MXPA02011990A

MXPA02011990A - Low weight cushioned carpet, carpet tile and method.

Info

Publication number: MXPA02011990A
Application number: MXPA02011990A
Authority: MX
Inventors: Scott C Miller
Original assignee: Milliken & Co
Priority date: 2000-06-05
Filing date: 2001-05-31
Publication date: 2003-05-27
Also published as: AU2001265249B2; CA2410155A1; JP2004500930A; EP1287199A2; WO2001094689A2; WO2001094689A3; AU6524901A; CN1451061A; CN1308540C

Abstract

An improved low weight cushioned flooring, floor covering, carpet, carpet tile, and method is provided. The low weight, cushioned carpet includes a low weight primary carpet having a base and a plurality of pile-forming yarns projecting outwardly from one side. A layer of reinforcement material is bonded to the base on the side opposite the pile forming yarns. The reinforcement layer is adjacent to and may be embedded in, a cushion layer of a polymer such as a polyurethane. An apparatus and process for forming the low weight cushioned carpet or carpet tile of the present invention are also provided.

Description

LOW WEIGHT CARPET CARPET, CARPET MOSAIC AND METHOD CROSS REFERENCE TO RELATED REQUESTS This application corresponds to a continuation-in-part and claims priority of the US patent application. Serial Number 09 / 587,654, filed June 5, 2000, and incorporated herein by reference. FIELD OF THE INVENTION The present invention relates to a padded surface cover, with foam backing or with cushion backing, wall cover, floor cover, flooring material, carpets, carpet mosaics or the like and more particularly at a low weight cushioned carpet, carpet mosaic and method. Also provided is a process and apparatus for forming the floor covering with cushion backing, carpet or carpet mosaic of the present invention. BACKGROUND OF THE INVENTION As described in U.S. Pat. Nos. 4,522,857, 5,540,968, 5,545,276, 5,948,500, and 6,203,881 (all incorporated herein by reference) carpet rugs and mosaics having cushioned backrests are well known to those skilled in the art. As described in the patent of the E.U.A. No. 5,948,500 and as illustrated herein, an example of a tufted carpet product is illustrated in Figure IA and an example of a bonded or agglomerated carpet product is illustrated in Figure IB. In the tufted carpet of Figure IA, a primary carpet fabric 12 is embedded in a layer of adhesive 16, where a layer of glass cloth or non-woven material is embedded. A foam base compound 19 is likewise adhesively bonded to the adhesive layer 16. In the tufted carpet illustrated in FIG. IA, the primary carpet fabric 12 includes a loop weight layer 20 tufted through primary backing 22 by a conventional tufting process supported on-site by a backing layer of latex pre-coating 24 or other suitable adhesives including a hot melt adhesive or the like. The foam base compound 19 of the tufted carpet product includes an intermediate layer 26 molded to a layer of urethane foam 28, as illustrated. The agglomerated or bonded carpet product (Figure IB) employs the same type of foam base compound 19 adhesively bonded by layers of adhesive laminate 16. However, the primary agglomerated carpet fabric 12 has somewhat different components from those of the tufted product, since it has yarns of hair cut 34 implanted in PVC, latex or hot melt adhesive 36 having a woven or non-woven reinforcement or substrate layer 38 of glass fiber, nylon, polypropylene or polyester. The practice employed to form the product described in US Pat. No. 4,522,857 and other known products, involves pre-forming and curing the foam base compound 19 of the backing material and urethane foam, by practices such as described in U.S. Patent Nos. 4,171,395, 4,132,817 and 4,512,831, issued to Tillotson (all here incorporated by reference). As described in these patents, only after this foam base compound is formed and cured to some degree as a modular component, is it laminated to the carpet base. As described in U.S. Pat. No. 5,948,500, the cost associated with these modular assembly and training practices can be reduced by a simplified operation in which a primary carpet fabric, either with or without a canvas stabilizing layer or the like, is placed directly on a polyurethane forming composition and subsequently cure the polyurethane. The process can be made even more efficient if the forming composition Polyurethane does not require pre-curing before joining the carpet base. Before the invention described in the U.S. patent no. No. 5,948,500, the known processes directed to the application from cushioned polyurethane backings to woven substrates were based on extremely tight temperature control on both the polyurethane composition and the attached fabric layer to effect stability through pre-cure of the polyurethane prior to lamination to a primary mat to form a composite structure. This pre-cure has been considered substantially necessary in order to produce a stable foam structure in which the primary carpet backing can be applied. The application of heat to the polyurethane composition prior to bonding the heated fabric backing causes polymer entanglement that has been deemed necessary to stabilize the foam mixture to a suient degree to prevent the foam from collapsing. The invention described in the patent of the U.S.A. 5,948,500 also provides a particularly simple reformable composite structure for the in-situ formation of a stable cushion carpet composite, which is not considered to have been previously employed. Specifically, it has not been previously recognized that a single The process could be used to carry all the layers of the cushioned carpet composite together, by placing a primary carpet fabric, either with or without a certain degree of preheating, directly into a mechanically foamed polyurethane forming composition, prior to curing the polyurethane and without an intermediate layer of material. As indicated, the carpet forming processes of the prior art typically require the separate formation of a foam base compound having a backing layer and a layer of urethane foam. The backing layer is then used as an intermediate layer in which a primary carpet layer and a reinforcement layer can be adhesively bonded. As described in the US patent. No. 5,948,500, the base of the primary carpet fabric, is adhesively bonded with a layer of nonwoven glass reinforcing material to form a preliminary compound. A puddle of polyurethane forming composition is deposited simultaneously through a woven or non-woven backing material. The preliminary compound and the polyurethane-forming composition subsequently meet almost immediately with the preliminary compound which is placed in and supported by the polyurethane-forming puddle. The entire structure is then heated to cure the polyurethane forming composition. The preliminary compound can heat slightly to approximately 49 ° C (120 ° F) to improve heating efficiency, although the process can also be carried out without this preheating. A carpet mosaic with upper cushion backing or carpet mosaic with modular cushion backing in the current market for example, sold under the brand Comfort Plus ™ by Milliken & Company of LaGrange, Georgia, has a primary mat weave with a frontal weight of approximately 678 to 1356 g / m2 (20 to 40 oz / yd2), a hot melt layer of approximately 1288.2 to 1830.6 g / m2 (38 a 54 oz / yd2), a cushion of approximately .254 to .508 cm (0.10 to 0.2 in) thick, weighing approximately 949.2 1152.6 g / m2 (28-34 oz / yd2) and having an approximate density of. 288 g / cc (18 pounds per cubic foot) and a total product height of approximately 1.02 to 2.03 cm (0.4 - 0.8 in). This carpet mosaic with upper cushion backrest, provides excellent resilience and comfort under the foot, exhibits performance characteristics that qualify it for very heavy commercial use and has achieved a remarkable status throughout the industry by having excellent appearance, feeling in the use, comfort and characteristics of cushion, performance, properties and similar. This carpet mosaic with upper cushion backing is relatively expensive to produce due to the high quality and quantity of materials used.

Although attempts have been made to reduce the cost of floor or carpet cover by employing lower quality materials, these attempts have not been particularly successful. Low quality products tend to have a look, feel, wear, comfort, cushion, and the like, less than desirable. Therefore, these products have not been accepted in the industry and have failed commercially. OBJECTIVES AND COMPENDIUM OF THE PRESENT INVENTION In view of the foregoing, a general objective of the present invention is to provide a surface cover with low weight foam cushion or backrest backing, wall covering, floor covering, flooring material, carpet or carpet mosaic. A further objective of the present invention is to provide a carpet or carpet mosaic having a low frontal, exterior or face weight. Another object of the present invention is to provide a carpet mosaic having a carpet with a front weight less than or equal to about 508.5 g / m2 (15 oz / yd2). Another object of the present invention is to provide a carpet mosaic having a hot melt or resilient layer less than or equal to about 1.695 g / m2 (50 oz / yd2).

Yet another object of the present invention is to provide a carpet mosaic having a light weight cushion. A further object of the present invention is to provide a carpet mosaic having a light weight cushion, with an approximate thickness of .1016 to .3048 cm. (0.04 to 0.12 inch), preferably a thickness of .1016 to .229 cm (0.04 - 0.09 inch). Yet another object of the present invention is to provide a carpet mosaic having a lightweight cushion with a density less than or equal to about .32 g / cc (20 pounds per cubic foot). Yet another object of the present invention is to provide a carpet mosaic having a lightweight cushion with a density of about 208 to 256 g / cc (13-16 pounds per cubic foot). A further objective of the present invention is to provide a carpet mosaic having a light weight cushion with a weight less than or equal to about 881.4 g / m2 (26 oz / yd2). A further object of the present invention is to provide a low weight modular carpet mosaic, which has resilience and comfort under the foot. Still another object of the present invention is to provide a low weight modular carpet mosaic which exhibits performance characteristics, which qualify it for heavy commercial use. A further object of the present invention is to provide a method for forming a low weight surface cover, wall cover, floor, carpet, carpet composite, carpet mosaic, or the like. Another object of the present invention is to provide a method for forming a low-weight modular carpet tile that has resiliency, comfort under the foot, and performance characteristic that qualify it for heavy commercial use. An object of the present invention is to provide a low-weight cushioned carpet mosaic or composite, wherein a reinforcing layer is placed, at least partially within a polymer mass that is adjacent to a primary carpet, with this primary carpet that it is placed in-situ in a puddle of polymer that forms the pad. A related object of the present invention is to provide a low weight cushioned carpet or mosaic composite, wherein a primary carpet fabric is attached to a reinforcement layer and placed in-situ in a non-submitted polyurethane forming composition. to a pre-cure operation.

A further objective of the present invention is to provide a process for the formation of a low weight cushion carpet mosaic or composite, wherein a reinforcing layer is adhered to the base of a primary carpet fabric, a polyurethane forming composition is applied to a nonwoven backing layer, and the primary carpet fabric with the adhered reinforcement layer is connected to the polyurethane forming composition, to form the carpet composite. A still further related objective of the present invention is to provide a continuous process for the in-situ formation of a cushioned carpet composite wherein a reinforcing layer adheres between a primary carpet base and a backing layer through the application. in-situ of a polyurethane-forming composition, without the need for an intermediate adhesion step. The present invention has as an additional related objective to provide an apparatus for carrying out continuous in-situ formation of a cushioned carpet composite. Yet another objective is that the low weight carpet and lightweight carpet mosaic composite of the present invention can be printed with independent orientation designs or designs having the same design. ability to join properly without cutting the mosaics in register with the design and allowing the carpet to be installed monolithically as well as by a conventional quarter-turn "parquet" or by ashler (brick). The preferred installation techniques are monolithic or ashler with or without floor adhesives. In accordance with an exemplary embodiment of the present invention, a low weight modular carpet composite that can be cut to form low weight modular carpet tiles includes a low weight primary mat or raw mat having, for example, a front weight less than or equal to approximately 508.5 g / m2 ( 15 oz / yd2), a hot melt layer less than or equal to approximately 1695 g / m2 (50 oz / yd2) and a lightweight cushion of approximately .1016 to .3048 cm (0.04-042 in) thickness. The cushion may have a density of about .208 to .256 g / cc (13-16 pounds per cubic foot) or less. This modular composite carpet of low weight or low weight modular carpet mosaic has unexpectedly been found to have excellent appearance, cushioned wear, resilience, comfort under the foot, and exhibits performance characteristics that qualify it for heavy commercial use. Therefore, this composite of low weight carpet or low weight carpet mosaic can be used in place of carpet mosaic with hard back or with standard heavy cushion backing, or wide carpet, in this way reducing the cost, reducing the material requirements, reducing the weight, reducing the energy requirements, reducing the environmental impact and similar. According to a particular example of the present invention, a modular carpet composite of low weight is cut into modular carpet mosaics or carpet tiles, for example 45.72 x 45.72 cm (18 X 18 in), 91.44 x 91.44 cm ( 36 X 36 in), 50 x 50 cm, lxl meter, 122 x 122 cm (48 X 48 in), or similar. Also, the low weight carpet or lightweight carpet mosaic composite of the present invention can be installed on-site or in floors by all conventional installation techniques as well as can be constructed for adhesive-free, self-adhering or similar installation. Also, the low weight carpet composite and the low weight carpet mosaic of the present invention can be printed with independent orientation designs or designs having the ability by proper stitching or joining without cutting the mosaics in register with the design and allow the carpet to be installed monolithically as well as by "parquet" of room of conventional turn or by ashler (brick). The preferred installation techniques are monolithic or ashler, with or without floor adhesives. According to the present invention, it has been unexpectedly discovered that a carpet or carpet mosaic composite having excellent seating, appearance, wear, resilience and comfort under the foot, and exhibiting performance characteristics that qualify it for heavy commercial use, It can be formed by combining a low weight primary carpet with a hot melt or resilient layer and a light weight cushion. In accordance with the present invention, a low weight modular carpet mosaic is provided having a total height of approximately .508 to 1.27 cm (0.20 to 0.5 in) in thickness, depending on the construction of the carpet mosaic (the number of layers or components) and that can be cut into any conventional shape or size. The light weight carpet composite of the present invention is especially adapted to be cut for use as low weight modular carpet tiles, but also finds applicability as other carpets or floors such as rugs, wide area rugs, floor mats or the like .

A feature of the present invention is to provide a low-weight carpet or carpet tile composite, which includes a primary carpet fabric in laminar relationship with a reinforcing layer wherein this reinforcing layer at least partially is embedded in a layer. of polyurethane foam that is placed adjacent to a non-woven backing layer. The reinforcing layer can be attached to the base of the primary carpet fabric by the polyurethane foam or by a separate adhesive. A feature of the present invention is to provide a low weight cushion carpet or carpet mosaic composite, which includes a primary carpet fabric in laminar relationship with a layer of polyurethane foam that is placed adjacent to a nonwoven backing layer. It is a feature of the present invention to provide a low weight carpet or carpet cushion composite, which includes a primary carpet fabric in laminar relationship with a reinforcing layer and a layer of polyurethane foam. The reinforcing layer can be attached to the base of the primary carpet fabric by the polyurethane foam or by a separate adhesive. A further feature of the present invention is to provide a process for forming a composed of cushioned carpet, which includes the simultaneous continuous steps of adhering a woven or non-woven reinforcement material with the base of a primary carpet fabric; depositing a puddle of polyurethane forming composition through a backing layer or support structure and placing the primary carpet fabric and reinforcing material adhered to the puddle of polyurethane forming composition deposited on the backing layer. A further feature of the present invention is to provide a process for forming a cushion carpet composite that includes 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 a layer of backup to the reinforcement material. A further feature of that of the present invention is to provide a process for forming a cushion carpet composite, which includes the simultaneous continuous steps of forming a primary carpet fabric; form a layer of polyurethane foam, and adhere the primary carpet fabric to the polyurethane foam layer. Another feature of the present invention is to provide a simple one-step process for forming a cushioned carpet composite that includes applying a polyurethane forming composition adjacent to a primary carpet fabric and a non-woven backing layer with the polyurethane-forming composition that at least partially supports an intermediate layer of reinforcing material. Yet another feature of the present invention is to provide a process for forming a cushion carpet composite that includes applying a polyurethane forming composition adjacent to a primary carpet fabric with the polyurethane forming composition that at least partially supports an intermediate layer of polyurethane material. reinforcement. Yet another feature of the present invention is to provide a process for forming a cushion carpet composite, which includes applying a polyurethane forming composition adjacent to a primary carpet fabric and a nonwoven backing layer. A still further feature of the present invention is to provide an apparatus for use in the continuous in-situ formation of a cushion carpet composite, wherein the apparatus includes a polymer application unit for depositing a polyurethane forming composition or other suitable polymer. in combination with an adhesive application apparatus for adhering a reinforcement layer to the base of a fabric of primary carpet. The polymer application unit and the adhesive application unit are simultaneously operable in controlled relation to each other such that the primary carpet with the adhered reinforcing layer can be placed directly on the polymer. A further feature of the present invention is to provide an apparatus for use in forming a cushion carpet composite wherein the apparatus includes a polymer application unit for depositing a polyurethane forming composition or other suitable polymer to the base of a fabric. of primary carpet. A still further feature of the present invention is to provide an apparatus for use in the formation of a cushion carpet composite wherein the apparatus includes an adhesive application apparatus for adhering a reinforcement layer to the base of a primary carpet fabric. In accordance with an aspect of the present invention, a cushioned, composite or mosaic carpet is provided. The padded carpet includes a primary mat having a primary base and a plurality of hair-forming yarns projecting outward from one side. A layer of reinforcement material is attached to the primary base on the side away from the hair-forming yarns.

The reinforcing material is adjacent to, and embedded at least partially in a polymer cushion layer such as polyurethane. Preferably there is no additional adhesive between the cushion layer and the layer of reinforcing material. An optional backing material is preferably placed on the bottom side of the cushion layer. The backing material may include an adhesive backing on the side away from the cushion layer. In accordance with one aspect of the present invention, a cushioned, composite or mosaic carpet is provided. The padded carpet includes a primary mat having a primary base and a plurality of hair-forming yarns projecting outward from one side. A layer of reinforcement material is attached to the primary base on the side away from the weight-forming yarns. The reinforcing material is adjacent to a polymer cushion layer such as polyurethane. An optional backing material is preferably placed on the bottom side of the cushion layer. The backing material may include an adhesive backing on the side away from the cushion layer. In accordance with one aspect of the present invention, a cushioned, composite or mosaic carpet is provided. The cushioned carpet includes a primary carpet that has a primary base and a plurality of hair-forming strands that project outward from one side. A cushion layer is attached to the primary base on the far side of the hair forming yarns. A reinforcing material can be embedded in the polymer cushion layer such as polyurethane. The cushion layer can be attached to the primary carpet by a hot melt layer. An optional backing material, preferably placed on the lower side of the cushion layer. The backing material may include an adhesive backing on the side away from the cushion layer. In accordance with another aspect of the present invention, a process for producing a cushioned carpet is provided. The process involves obtaining a primary carpet fabric, comprising a plurality of hair-forming yarns extending outward from one side of a primary base. A layer of reinforcing material adheres to the primary carpet fabric on the side, from where the weight-forming yarns do not extend, thus forming a preliminary composite. A polymer puddle such as a polyurethane-forming composition is applied to one side of a backing material and preferably doctor cut to the desired thickness to form a cushion layer. The preliminary compound is then adhered to the cushion layer. After This coupling operation, the carpet is cut to size or in mosaics. In accordance with another aspect of the present invention, a method for producing a cushioned carpet is provided. The method involves obtaining a primary carpet fabric, comprising a plurality of weight-forming yarns extending outward from one side of a primary base. A polymer puddle such as a polyurethane-forming composition is applied to one side of a backing material and preferably doctor cut to the desired thickness. The primary carpet fabric is then placed in the uncured polymer puddle. Following this coupling operation, the polymer is preferably heat cured and the carpet is cut into tiles. In accordance with another aspect of the present invention, a method for producing a cushioned carpet is provided. The method involves obtaining a primary carpet fabric, comprising a plurality of hair-forming yarns extending outward from one side of a primary base. A layer of reinforcing material adheres to the primary carpet fabric on the side, from where the hair-forming yarns do not extend, thus forming a preliminary composite. A polymer puddle such as a composition Polyurethane former is applied to one side of the backing material and preferably cut with doctor blade to the desired thickness. The preliminary compound is then placed on the uncured polymer puddle. Following this coupling operation, the polymer is preferably heat cured and the carpet is cut into tiles. According to yet another aspect of the present invention, there is provided an apparatus for use in forming a cushion carpet composite, comprising: a reinforcing bonding unit for attaching a layer of reinforcing material to the inner side of a carpet fabric primary, to form a preliminary carpet composite; a polymer application unit for supplying a polyurethane-forming composition through the surface of a carrier fabric; a coupling unit for placing the preliminary carpet composite in the polyurethane forming composition; and means for heat-curing the polyurethane-forming composition subsequent to the preliminary compound placed in the polyurethane-forming composition; wherein the reinforcing joint unit, the polymer application and the coupling unit are operable in a simultaneous and continuous manner. According to still another aspect of the present invention, an apparatus for using in forming a cushion carpet composite, comprising: a reinforcing joining unit, for attaching a layer of reinforcing material to the underside of a primary carpet fabric, to form a preliminary carpet composite; a polymer application unit for supplying a polyurethane-forming composition through the surface of a carrier fabric; means for thermo-curing the polyurethane forming composition, to form a cushion layer and a coupling unit for joining the carpet composite and cushion layer. According to yet another aspect of the present invention, there is provided an apparatus for use in forming a cushioned carpet composite, comprising: a reinforcing joining unit for attaching a layer of reinforcing material to the underside of a carpet fabric primary and the upper side of a cushion layer to form a carpet composite. According to another embodiment of the present invention, a modular carpet mosaic is manufactured by: tufting wide carpet to a weight of 508.5 g / m2 (15 oz / yd2) or less, print a design in the form of a wide carpet, apply a cushion backing system, and cut into square tiles.

The low weight modular carpet mosaic of the present invention is aesthetically pleasing and exhibits performance characteristics that qualify it for a heavy commercial application. The combination of a low weight tufted rug <508.5 g / m2 (<15 oz / yd2), hot melt layer and cushion backrest also provides resilience and comfort under the foot. The low weight, composite and mosaic carpet of the present invention are especially suitable for broad carpets due to: a. Tufted construction b. Applied design c. Attached or added cushion backing The low weight, composite and mosaic mat of the present invention are well suited for modular applications due to: a. Post-applied design b. Tufted construction c. Cushion backing BRIEF DESCRIPTION OF THE DRAWINGS Figure IA is a sectional view of a tufted carpet with a composite structure welded.

Figure IB is a side sectional view of an agglomerated carpet incorporating a composite welded structure. Figure 2 is a schematic view illustrating an exemplary embodiment of the apparatus and process of the present invention. Figure 2A is a schematic view illustrating a modified embodiment of the apparatus and process of Figure 2, with the latex latex coating added during the process. Figure 3A is a side sectional view of a tufted carpet, incorporating a structure formed by the apparatus and process of the present invention as illustrated in Figure 2. Figure 3B is a side sectional view of an agglomerated carpet that it incorporates a structure formed by the apparatus and process of the present invention as illustrated in Figure 2. Figure 4A is a sectional side view of an alternate embodiment of a tufted rug having no reinforcing layer. Figure 4B is a sectional side view of an alternate embodiment of an agglomerated carpet that does not have a reinforcing layer.

Figure 5 is a schematic view illustrating an alternate apparatus and process according to the present invention for forming a cushion carpet composite without separate adhesive bond between the primary carpet and the reinforcement layer. Figure 5A is a schematic view showing a modified embodiment of the apparatus of Figure 5, without the addition of a reinforcing layer. Figure 6A is a sectional side view of an alternate structure of a tufted carpet formed by the apparatus and process illustrated in Figure 5. Figure 6B is a sectional side view of an alternating structure for an agglomerated carpet formed by the apparatus and process illustrated in Figure 5. Figure 7 is a schematic view illustrating yet another alternate apparatus and process in accordance with the present invention, to form a cushioned carpet composite without separate adhesive bond between the primary carpet and the reinforcement layer as illustrated in Figures 6A and 6B. Figures 8A and 8B are schematic, simple, and more complex flow diagrams of the production of the low weight modular carpet tiles, according to selected embodiments of the present invention.

Figure 9 is a tabular representation of materials, dimensions, temperatures and the like employed in the process of Figure 8. Figures 10-18 are side views in cut of carpet, composite or low weight agglomerated and tufted mosaics respectively in accordance with different embodiments or aspects of the present invention. Although Figures 10A and 11-18 show a looped hair in the primary carpet and Figure 10B shows a primary agglomerated carpet, it should be understood that an agglomerated or tufted loop and / or cut pile can be used and that the pile can be sculpted , printed, dyed and / or similar, as desired. Figures 19 and 19A are respective schematic illustrations of alternate apparatus and process according to selected embodiments of the present invention. Figure 19 is a schematic view showing still another alternate apparatus of the present invention without felt. Figure 19A is a schematic view illustrating yet another alternative embodiment of the apparatus and process of the present invention without felt (secondary backing) or thin canvas (reinforcement layer). While the invention will be described and illustrated in connection with certain embodiments and Preferred methods, it is by no means intended to limit the invention to these specific modalities and procedures. On the contrary, it is intended to cover all these modalities, procedures and alternate modifications that may fall within the spirit and real scope of the invention as defined and limited only by the appended claims. DETAILED DESCRIPTION In accordance with the present invention, a low weight surface cover, wall cover, floor, carpet, floor covering, carpet compound, or modular carpet mosaic and method are provided, which are aesthetically pleasing, exhibit performance characteristics that qualify them for heavy commercial use , have resilience and comfort under the foot, and can be dyed, printed and installed as can be done with cushion back rugs or foam backs, composites or conventional mosaics. A schematic view illustrating an exemplary apparatus and process used to form the padded, low weight, wall cover, floor, floor covering, carpet or mosaic cover of the present invention is illustrated in Figure 2. The apparatus is generally designed by the reference number 100. As illustrated, a primary carpet fabric 112, which can incorporating either a tufted or agglomerated configuration (with loop and / or cut pile) as described above, is extracted from an assembled carpet roll 114. As previously indicated, the primary carpet fabric 112 preferably includes a plurality of hair-forming threads, projecting outward from one side of a base or primary backing. If the primary carpet 112 employed in the present invention is a tufted carpet, its configuration will preferably be adapted to the primary carpet 12 illustrated with respect to that in Figure IA, whereas if the primary carpet 112 employed in the present invention is a product. agglomerated, its configuration will be of the primary mat 12 illustrated in Figure IB. It is contemplated that the primary mat 112 may include one or more base or backing layers. It will be understood that, as with the prior art products, where a primary tufted or agglomerated carpet fabric 12 can have different modalities, the primary carpet weave component structure is not critical to the present invention. Instead, it is intended that any low weight primary carpet fabric (low outer or front weight) having a hair-forming portion and a primary base can be used as the carpet fabric primary. By "primary base" is meant any single or composite layer structure including, inter alia, the composite in commonly used layers of primary backing 22 and latex pre-coating 24 previously described in relation to the tufted product (Figure IA) and the adhesive layer 36 with the reinforcement substrate 38 previously described in relation to the agglomerated product (Figure IB). As will be appreciated, the use of polyester in the primary base structure may be convenient due to the eventual thermal cure that this structure can undergo. Other modalities, such as those that can occur to those with skill in the specialty, can of course also be employed. For example, in the agglomerated product, the hair-forming yarns can be thermally adhered to the substrate 38 as described in US Pat. No. 5,443,881 (incorporated herein by reference) to allow simplified construction of a primary carpet. Alternate modes including those described in the patent of the U.S.A. No. 4,576,665 issued to Machell (incorporated herein by reference) may equally be employed. For example, it is contemplated that specialized primary backings such as non-woven structures comprising glass fibers sandwiched between polyester layers can be employed in the tufted carpet primary to impart the desired properties relating to stability, thereby potentially reducing or even eliminating the need for secondary backing or latex pre-coating currently employed. Furthermore, it is contemplated that if a pre-coating is to be used, it can be added directly on-line in an operation before any adhesive operation. With respect to one embodiment, in the tufted carpet of the present invention (Figure 3A), the primary carpet fabric 112 preferably comprises a loop weight layer 120 of tufted pile yarns in a primary backing 122 as is well known and held in place by a pre-coating of adhesive 124 such as latex or hot melt adhesive. It is contemplated that latex or hot melt adhesive may be added on-line after removal of the carpet roll before application of any other adhesive as described below. The carpet can be steam treated after the pre-coating is added to facilitate subsequent printing operations if desired, to reduce stress. The two basic primary backup constructions are woven polypropylene and non-woven polyester. Each material can have a variety of engineering construction features for a specific end use. The material of Preferred primary backing is 20 weft threads per 2.54 cm (inch) of woven polypropylene, with fleece or nylon plush fabric needle punched. According to an example of the present invention and with reference to Figure 2A of the drawings, the primary carpet 112 is a tufted tufted pile carpet formed by tufting, for example a non-thermo-fixed filament through the primary backing, then washing, steam-treating, drying and injecting or jetting a design, color or pattern preferably monolithic or independent of orientation to form for example a primary carpet precursor with a width of 3.66 m (12 feet) 120 and primary backing 122 When using a non-thermo-fixed filament, and originally tufting the filament to a rather long loop length, the steps of washing, steam treatment, drying and dyeing shrink the filament to form tighter and smaller loops and provide a denser surface to the primary carpet precursor. Next, this primary carpet precursor is divided in half and rolled to form two rolls with a width of 1.83 meters (six feet) spaced 115 from the divided primary carpet precursor 113 (Figure 2A). Next, a roll 115 of the divided primary carpet precursor 113 is used as the initial carpet feed and the apparatus of Figure 2A. The latex pre-coating or hot melt adhesive coating 124 is added to the back of the primary carpet precursor 113 to form a primary carpet fabric 112 in the upper section of the apparatus of Figure 2A downstream of the accumulator 150 and upstream of the reinforcement joint unit 155. For example, a thin layer of latex pre-coating 119 is applied to the back of the primary carpet precursor 113 using a coating roller 117. In accordance with one embodiment of the present invention, the primary carpet precursor (which does not have a latex pre-coating) is wound or coiled with the primary backing 122 exposed (Figures 19 and 19A). Also, it is contemplated that the apparatus and process of the present invention can include the entire assembly process from tufting the filament into the primary backing, dyeing the tufted filament, pre-coating the back of the primary backing with latex, coating with fusion on Heat the fiberglass reinforcement material, foam-coat the secondary felt backing, laminate the primary mat, reinforce with fiberglass and the foam padding layer, heat or cure the laminate, and cut the carpet compound into mosaics of carpets, continuous carpets or pasacaminos, carpet of area or similar. Also, it is contemplated that according to the present invention, the process can be decomposed in its respective steps and carried out in a batch mode instead of a continuous one, although the continuous mode of operation is preferred. For example, the primary carpet can be formed in one operation and placed in rolls. The cushion backing or the foam layer can be formed in a separate operation and placed on a roll. The two can be joined by a coupling unit using an adhesive, hot melt, hot melt with reinforcing layer or the like. In the agglomerated carpet of the present invention (Figure 3B), the primary carpet fabric 112 preferably comprises a plurality of cut pile yarns 134 implanted in an adhesive 136 such as a latex or hot melt adhesive which is laminated to a reinforcement layer or substrate 138 of a woven or non-woven material including glass fiber, nylon, polyester or polypropylene. It is contemplated that this substrate layer 138 may be pre-coated with latex or other thermoplastic polymers to allow fusion adhesion to the cut pile yarns 134 upon application of heat, thereby potentially reducing or eliminating the need for latex or adhesive. hot melt 136.

The wires 120, 134 can be spun yarns 0 threads and preferably are formed from a polyamide polymer such as short fibers of nylon 6, nylon 6 yarn, or short fibers of nylon 6,6, nylon thread 6,6, available from DuPont Fibers in Wilmington, Del., Although other suitable natural or synthetic yarns may equally be employed as will be recognized by those skilled in the art. By way of example only and not limitation, other materials that may be employed, include short polyester or yarn fibers such as polyethylene terephthalate (PET), and polybutylene terephthalate (PBT); polyolefins, such as filament or short fibers of polyethylene and polypropylene; rayon; and polyvinyl polymers, such as polyacrylonitrile, wool, nylon / wool blends, Lyocell, rayon, saran, acetate, glass, aramid, fluorocarbon, sulfur, acrylic, Peleo, olefin, melamine, polybenzimidazole and combinations thereof. A variety of deniers, layers, levels of twisting, air matting and heat setting characteristics can be used to build the yarn. The preferred yarn is nylon 6,6, filament, 1360 denier, 1 layer, without twisting, without matting, and without heat setting. Another filament is nylon 6,6, filament, 1350 deniers, without layers, normal twisted (0-1 twisted), without heat setting.

In the tufted product, the adhesive pre-coating 124 is preferably butadiene styrene rubber latex (SBR) but other suitable materials such as polyvinyl chloride (PVC), ethylene vinyl acetate (EVA), polyurethane, acrylic and fusion adhesives In hot as they are well known by those with skill in the specialty, they can equally be used. In the case that a hot melt adhesive is used, it is contemplated that a reinforcing material such as glass canvas can be directly connected to form a composite laminate without the use of adhesives. Furthermore, as previously indicated, it is contemplated that the adhesive pre-coating 124 can be totally removed in the tufted product, if the loop pile 120 is tufted in a suitably stable relationship to the primary backing 122. The hot fusions commonly employed They are bitumen, thermoplastic based on polyolefin and polyurethane. The preferred hot melt material is polyolefin-based thermoplastic. Again with reference to Figure 2, in potentially preferred practice, the primary carpet fabric 112 is transported by a plurality of rollers through an accumulator 150, as is well known in the art to a reinforcing joint unit 155. Simultaneously with the transportation of the Primary carpet fabric 112 to reinforcing bonding unit 155, a sheet of reinforcing material 158 is likewise transported to reinforcing bonding unit 155. Reinforcing material 158 preferably non-woven fiberglass material such as a tissue or fiberglass mat of 67.8 g / m2 (2.0 oz / yd2) containing a urea formaldehyde binder, although alternate materials may include woven glass, woven polyester and non-woven polyester. In the reinforced bonding unit 155, an adhesive 160 (Figures 3A, 3B) such as hot melt adhesive, is preferably applied to the reinforcing material 158 by a film coating applicator or other such unit as are well known. . The reinforcing material 158 and the primary carpet fabric 112 are subsequently preferably passed in coupling relationship between joining members such as rolls 163, 165, thereby bonding the reinforcing material 158 to the underside of the primary carpet fabric 112. That is, the reinforcing material 158 is attached to the side of the primary carpet fabric 112 from which the hair-forming yarns do not project. The union of the reinforcing material 158 to the underside of the primary carpet fabric 112, produces a preliminary compound 166 which is subsequently placed in a polymer puddle or foam-forming composition such as a polyurethane-forming composition as described below. Although the reinforcing joint unit 155 is illustrated in its preferred embodiment incorporating a film coating applicator, it will be understood that alternate equivalent means such as application rolls, spray heads and the like may also be employed. By way of example only and not limitation, alternative means are described for the application of adhesive 160 in the US patent. No. 4,576,665 granted to Machell. In preferred practice, while the preliminary compound 166 is formed, a backing material 170 such as a non-woven backing is passed through an accumulator tray 172 to a polymer application unit 175 that preferably includes a discharge unit. of polymer 176 and a doctor blade 177. The backing material 170 is coated with a polymer 178 such as a polyurethane-forming composition as described more fully below. In the preferred embodiment, the backing material 170 is woven or non-woven synthetic fiber material such as 10% to 100% polyester / polypropylene, preferably 50% polyester, 50% non-woven fibrous polypropylene material that is available from Spartan Mills Company in Spartanburg, S.C. While this represents the preferred backing material, it will be understood that any number of alternate compositions can equally be used as dictated by the requirements regarding shrinkage and installation. Secondary backing materials commonly employed include nonwoven polyester, nonwoven polyester and polypropylene blends, or woven polypropylene. By way of example only, in instances where very little shrinkage or no shrinkage can be tolerated, the backing material can be up to 100% polyester. Further, while a non-woven backing material may be preferred, it is contemplated that woven or non-woven constructions may be employed as materials other than polyester, polypropylene and polyester / polypropylene such as nylon, fiberglass and the like. The thickness of backing material 170 preferably varies in the range from about 0.0254 to .483 cm (0.01 to about 0.19 in), although a range between about 0.127 to 0.3048 cm (0.05 and 0.12 in) may be more preferred. . As indicated, in preferred practice, the polymer application unit 175 applies a deposit of a polymer 178 (Figures 3A, 3B) to the backing material. 170 after which the height of the polymer is cut with doctor blade to a desired level. In preferred practice, the applied polymer 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 incorporates a silicone surfactant to improve both the foaming ability and the stability of the polyurethane or "puddle" layer extending across the surface of the backing material 170. The density of foam commonly used is .288 g / cc (18 pounds per cubic foot) with a thickness greater than .254 cm (0.10 inch). The preferred density is .256 g / cc (16 pounds per cubic foot) with a thickness of .152 cm (0.06 in). The preferred polyurethane forming composition for use in the present invention is described in U.S. Pat. No. 5,104,693 granted to Jenkins, the teachings of which are hereby incorporated by reference. Specifically, the preferred polyurethane forming composition that is applied across the surface of the carrier backing 170 includes: A. at least one isocyanate reactive material having an average equivalent weight of from about 1000 to about 5000; B. an effective amount of a blowing agent; Y C. A polyisocyanate in an amount to provide an isocyanate index of between about 90 and about 130, wherein at least 30 weight percent of this polyisocyanate is a soft segment pre-polymer reaction product of a stoichiometric excess of diphenylmethane diisocyanate (MDI) or its derivative and an isocyanate-reactive organic polymer having an equivalent weight from about 500 to about 5,000 and wherein the prepolymer has an NCO content of about 10 to about 30 weight percent. The polyurethane-forming composition also preferably contains a silicone surfactant to improve the foaming ability and stability in the form of an organo-silicone polymer as generally described in US Pat. No. 4,022,941 granted to Prokai and collaborators, the teachings of which are incorporated herein by reference. Specifically, the preferred surfactant is preferably a linear siloxane-polyoxyalkylene block copolymer (AB) and specifically a polyalkyleneoxydimethylsiloxane copolymer. A similar silicone surfactant that 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. A sufficient level of the silicone surfactant is used to stabilize the cells of the foaming reaction mixture until curing occurs to allow the preliminary compound 166 to be placed in the puddle of the uncured polyurethane forming composition, without destabilizing the layer of this polyurethane forming composition placed across the surface of the backing material 170. In general, the silicone surfactants are preferably used in amounts in the range from about 0.01 to about 2 parts per hundred parts by weight of the component (A ) and more preferably from about 0.35 parts to about 1.0 part by weight of component (A) and more preferably from about 0.4 to 0.75 part per hundred parts by weight of component (A). As previously indicated, after arranging the polymer through the backing material 170, the layer or "puddle" of deposited polymer is preferably cut with doctor blade at a pre-determined height by a doctor blade located in the doctor unit. polymer application 175. While a simple mechanical doctor blade is preferred, alternate equivalent means such as an air knife or the like, can also be employees. This air knife is described, for example, in US Pat. No. 4,512,831 issued to Tillotson (here incorporated by reference). In one embodiment of the present invention, the primary carpet fabric 112 that is preferably bonded to the reinforcing material 158 to form the preliminary compound 166, is placed directly into the polyurethane-forming composition, immediately after it is cut with a doctor blade. at the appropriate level without any need for significant heating either of the preliminary compound 166 or the polyurethane-forming composition. Accordingly, the preliminary compound 166 and the backing material 170 with the applied polyurethane-forming composition, can be delivered simultaneously at room temperature to a coupling roll 180 immediately after application and doctor blade cutting of the film forming composition. polyurethane. As will be appreciated, this avoids the delay time between forming the cushion carpet composite components, which allows highly efficient processing easily controllable either manually or by computer control means (not shown) as is well known from those with skill in the specialty. In the preferred process, the preliminary compound 166 may be slightly preheated to improve operational control during rolling and curing, but this preheating is not essential for the formation of the desired product. In the illustrated and preferred embodiment of the carpet, the process described above results in the layer of reinforcing material 158 which is placed adjacent to and at least partially embedded in the polyurethane layer 178. That is, the reinforcing material 158 is preferably in intimate contact with the polyurethane 178, such that the polymer material is bonded to the reinforcement material and will maintain the reinforcement in place. Once the preliminary compound 166 has been placed in the polyurethane-forming composition, the resulting compound can be heated in a heating unit 182 by conductive, radiant or convection heaters as is well known in the art. They can refer to conductive heaters by contact. This heating can be carried out at temperatures between about 121 ° C (250 ° F) and about 163 ° C (325 ° F) for between about 2 and 8 minutes. The resulting foam or cured foam cushion layer (Figures 3A, 3B) that are produced in this manner has a density of between about 192 g / cc (12 pounds per cubic foot) and about .23 g / cc (20 pounds). per cubic foot) preferably between approximately .224 and .256 g / cc (14 and 16 pounds per cubic foot) and more preferably .256 g / cc (16 pounds per cubic foot). After the thermal curing operation, the padded carpet composite that is formed can be passed over a unidirectional heat source 185, such as a roll heater or plate heater at about 204 ° C (400 ° F) to melt any fibers protruding into the backing material 170 on a smooth surface. The carpet compound that is formed, will later be rolled, cut, sliced or similar. When carpet mosaics are produced, it is preferred that they be cut into carpet tiles almost immediately (instead of being rolled) to avoid any unwanted kinking or cupping. After the carpet tiles are cut from the composite, they are stacked, packaged and stored or shipped to the customer or store. It will be appreciated that a number of alternative practices may be incorporated in the present invention that generate slightly different products. By way of example only, the reinforcing material 158 can be left completely out of the process, thus making use of the adhesive application apparatus 155 and adhesive 160 completely unnecessary. In these cases, the primary carpet fabric can be placed directly in the polyurethane forming composition, in this way producing a composite structure as illustrated in Figures 4A and 4B with the polyurethane 278 immediately adjacent to the primary carpet fabric 212 and as described in U.S. Pat. No. 6,203,881 incorporated herein by reference. According to another embodiment, when the cushion layer is preformed rather than in-situ, a hot melt layer can be used to couple the primary carpet with the cushion layer or without the reinforcing material (Figure 12). This process described in the U.S. Patent. No. 4,522,857 is incorporated herein by reference. Still in another potential alternative, the backing 170, 270 may have a rapid release backing of adhesive connected to the face in which the urethane-forming composition is not applied. As will be appreciated, this quick release backing will allow the carpet to be easily installed and removed, without damaging the polyurethane cushion 178, 278. Furthermore, it is contemplated that in some instances the backing 170, 270 can be completely removed, so such that the polyurethane cushion 178, 278 directly contacts the floor as described in relation to the US Patent No. 4,286,003 which is incorporated herein by reference. Also, an adhesive-free carpet and method is described, for example, in the U.S. Patent application. Co-pending Serial No. 09 / 513,020 filed on February 25, 2000, and titled "Adhesive-Free Carpet Tiles and Carpet Tile Installations." (Adhesive-free carpet mosaics and carpet tile installations) (incorporated herein by reference) . It is preferred that carpet tiles for adhesive-free installations have a cup of approximately .476 cm (3/16") or less and a curl of .159 cm (1/16") or less. Although it is preferred that the interlaced surface covering, low weight interlaced modular carpet or low weight modular carpet mosaic of the present invention have the following layers: yarn, primary backing, latex pre-coating adhesive, hot melt adhesive , glass fibers, polyurethane foam and felt (Figure 10A), it is contemplated that one or more of these layers may be removed or replaced and still provide a low weight carpet or mosaic having the desired characteristics or properties. For example, the latex pre-coating adhesive layer can be replaced by a hot-melt layer of bitumen (Figure 11), the felt layer can be removed in a free installation installation product (without floor adhesive) (Figure 16), the glass layer can be removed (Figure 12) or similar.

An alternate process and apparatus for producing a cushion carpet composite in accordance with the present invention is illustrated schematically in Figure 5. As illustrated, a primary carpet fabric 312 having any of an encapsulated or bonded configuration is removed from a mounted carpet roller 314, through an accumulator 350 in the same manner described above. Simultaneously with the supply of the primary carpet fabric 312 to the coupling roll 360, a reinforcing material 358 such as a non-woven glass is supplied to a polymer contact roll 360 or similar device such as an extrusion coating applicator. . The contact roll of the polymer 360 is preferably in contact with both the surface of the reinforcing material 358 and an accumulation of a polymer 378 such as the previously described polyurethane formulating composition. The polymer contact roll 360 serves to collect a portion of the polymer 378 and pass the polymer over and through the reinforcing material 358. Simultaneously with the passage of the polymer through the reinforcing material 358, a backing material 370 such as the polyester / non-woven polypropylene described above is preferably passed in adjacent coupling relationship with the reinforcing material polymer coated 358 between the polymer contact roll 360 and the backup material coupling roll 379. A doctor blade 377 serves to control that the depth of the polymer not passing through the reinforcing material 358 in contact with the material backing 370. Thus, it will be appreciated that a polymer sandwich structure is preferably formed which compresses a layer of backing material 370, a relatively thin layer of polymer 378 such as polyurethane that has been passed through a reinforcing material layer 378 and a doctor cut polyurethane blade 378 that is not passed through reinforcing material 358. This polymer sandwich structure can then be passed to coupling roll 370 for bonding with the primary carpet fabric 312, by placing the primary carpet fabric 312 directly on the doctor blade cutting layer of the urethane polymer 378 without any to pre-cure operation. Subsequently, the compound is heated, cured and rolled or cut. A potentially preferred configuration for a resultant tufted carpet composite is illustrated in Figure 3A. As shown, the reinforcing material 358 will be at least partially enclosed by and embedded in the polyurethane 378. As illustrated, it contemplates that the pre-coating layer can be removed in the tufted structure since the tufts can be held in place by the polyurethane 378. A potentially preferred configuration for a resultant agglomerated carpet composite is illustrated in Figure 6B. With respect to Figures 5A and 18 of the drawings, the reinforcement material and the hot melt layers can be removed simply by not feeding the reinforcement 358 together with the felt 370 and the primary mat 312. An additional alternating process and apparatus for joining all layers of the cushion carpet composite is illustrated in Figure 7. As shown, a layer of reinforcing material 358 is preferably passed adjacent to a polymer contact roll 370 that is in simultaneous bearing contact of both the material of reinforcement 358 as a polymer reservoir 378. The polymer contact roll 360 serves to disperse a portion of the polymer 378 through the reinforcing material 358 to create a coating on both sides. The reinforcing material 358 with its polymer coating 378 is then bonded in a laminated structure to the primary carpet cell 312 and a layer of backing material 370 by passage through the attachment point between the doctor blade 377 and the roll of coupling backup material 379.

Subsequently, the compound is heated, cured and rolled or cut. This practice will produce a composite structure of short carpet with doctor blade substantially similar to those illustrated in Figures 6A and 6B. According to one aspect of the present invention, the designs that are printed on the low-weight modular carpet or carpet mosaic are preferably characterized as independent of orientation or having the ability to properly bond or seam without cutting the mosaics in register with the design. The techniques used to create this design make it possible to install the modular carpet monolithically instead of a quarter turn or ashler. The commonly used techniques of installing modular carpet such as monolithic parquet and ashler (brick) can be used to install carpet or carpet mosaic of low weight of the present invention. The preferred technique is monolithic or ashler. Also, a floor adhesive may or may not be used depending on whether the carpet or tile is designed for adhesive-free installation or installation with conventional adhesives. Also, the carpet tile can be self-adhesive and contain a quick release backing of adhesive attached to the face of the back 170, 270 opposite the polyurethane foam.

With reference to Figures 19 and 19A of the drawings, the felt and hot melt layers can be removed for example by feeding the primary carpet 314 through an apparatus similar to that shown in Figures 5 of the drawings, except that the The carpet is inverted and the polymer layers are applied directly to the reinforcing material and / or lower surface of the primary carpet. With respect to Figures 17 and 17A of the drawings, the reinforcing material such as glass is removed by not feeding the reinforcing material together with the carpet and polymer. According to an example of the present invention, the low weight modular carpet mosaic of Example I below was tested using the hexapod test as described below.

Test Method Conducted Hexapod Drum Tester ASTM D-5252 Hexapod Jogger ISO / TR 10361 CRI TM-101 Photo Scale Ratings APPARATUS: HEXAPOD SWALLOW CARPET TESTING DEVICE WIRA INSTRUMENTATION PROCESS: The test specimen is subjected to the reported "hexapod" tumbling cycles by removing the specimen every 2,000 cycles for vacuum restoration. An Electrolux vertical vacuum (Discovery II) was used, making four (4) runs or passes back and forth along the specimen. The samples were estimated using vertical lighting equivalent to daylight (1,500 lux). Samples were viewed at a 45 ° angle from a distance of 1.5 meters, judging from all directions. The samples were also measured for hair height before and after and tested to obtain a hair height retention value. TEST RESULTS The invention may further be understood by reference to the following examples which are not to be considered as unduly limiting the invention to be defined and considered in the light of the appended claims. EXAMPLE I A tufted carpet is produced by the apparatus and process as illustrated and described in relation to Figure 2. The carpet produced has the configuration illustrated and described in relation to Figure 3A. The production parameters were as follows: Filament 508.6 g / m2 (15 ounces per square yard) nylon 6,6 Continuous filament of loop hair. Primary backing Non-woven polyester of 135.6 g / m2 (4 ounces per square yard.) Pre-Coating Latex SBR 542.5 g / m2 (16 ounces per square yard) with 100 parts CaC02 filling. Hot Melt Adhesive Propylene modified 1424 g / m2 (42 ounces per square yard.) Reinforcement Laminate Non-woven glass of 67.8 g / m "(2 ounces per square yard) with acrylic binder Urethane foam coverage 678. g / m2 (20 ounces per square yard.) Urethane foam density .256 g / cc (ounces) per cubic foot.) Polyester Backing Material) Non-woven, 135.6 g / m2 (4 oz. Per square yard.) (50% polypropylene, 50% polyester) EXAMPLE II Construction Empenachado, hair in textured loop, interlaced 100% WearOnMR Nylon Front Fiber Milliken certified. MilliGuard ™ Antimicrobial BioCare ™ Stain Remover Dyeing Method MillitronTM ™ Colour Injection Printing Caliber 39.4 / 10 cm (.1 / 10") Stretch 56.7 / 10 cm (14.4") Embossed 2230.3 / 100 square centimeter (143.9 / square inch) Standard backrest PVC-free UNDERSCOREMR cushion Total Nominal Thickness 8.6 mm (0.34") Total Weight 3,387.4 grams / square meter (99.9 ounces / square yard) Mosaic Size 914.4 X 914.4 mm (36 x 36") Flammability (Radiant Panel ASTM-E-648) (Class I) > 0.45 Smoke density (NFPA-258 -T or ASTM-E-662) < 450 Self-Extinguishing Metenamine Pill Test (CPSC FF-1-70 or ASTM D 2859) Light Firmness (AATCC 16E) > 4.0 to 80 hours. Loss of color by light (AATCC 165) > 4.0 wet or dry Static Electricity (AA TCC-134) 20% R.H. 21.1 ° C (70 ° F) < 3.5 KV Dimensional Stability - Aachener Test < 0.2% (Standard DIN 54318) Recommended Traffic Heavy commercial Maintenance Recommended MillicareMR Indoor air quality CRI Product Type: 12200793 EXAMPLE III Constructed construction, textured loop pile, interlaced Milliken-certified WearOnMR Nylon Front Fiber MilliGuard ™ Anti-Grime BioCare Anti-Microbial Dyeing Method Millitron ™ Color Dye Printing Caliber 39.4 / 10 cm (.1 / 10") Rows 56.7 / 10 cm (14.4" ) Embossed 2230.3 / 100 square centimeter (143.9 / square inch) Standard backing PVC-free UNDERSCOREMR cushion Total Nominal Thickness 8.6 mm (0.34") Total Weight 3,387.4 grams / square meter (99.9 ounces / square yard) Mosaic Size 914.4 X 914.4 mm (36 x 36") Flammability (Radiant Panel ASTM-E-648) (Class I)> 0.45 Smoke Density (NFPA-258-T or ASTM-E-662) < 450 Test Metenamina Auto Extinguishable Pill (CPSC FF-1-70 or ASTM D 2859) Firmness to Light (AATCC 16E)> 4.0 to 80 hours.

Loss of color by light (AATCC 165) > 4.0 wet or dry Static Electricity (AA TCC-134) 20% R.H. 21.1 ° C (70 ° F) < 3.5 KV Dimensional Stability - Aachener Test < 0.2% (DIN Standard 54318) Recommended Traffic Heavy commercial Maintenance Recommended MillicareMR Indoor air quality CRI Product Type: 12200793 EXAMPLE IV A tufted rug is produced by the process apparatus as illustrated and described in relation to Figure 2. Carpet has the configuration illustrated and described in relation to Figure 3A. The production parameters are as follows: Straight thread of nylon 6,6 loop pile of 406.9 g / m2 (12 ounces per square yard) white, 1350 deniers, non-folded, non-woven, non-thermo-fixed Primary backing Non-woven polyester of 135.6 g / m2 (4 ounces per square yard) Pre-coating Latex SBR 542.5 g / m2 (16 ounces per square yard) with 100 parts load of CaC02 Hot melt adhesive Modified polypropylene 1220.7 g / m2 (3 ounces per square yard) Laminated reinforcement Non-woven glass of 67.8 g / m2 (2 ounces per square yard) with acrylic binder. Polyurethane foam coverage 508.6 g / m2 (15 ounces per square yard.) Urethane foam density .256 g / cc (16 pounds per cubic foot) Backing Material Non-woven (50% polypropylene, 50% polyester) 135.6 g / m2 (4 ounces per square yard) EXAMPLE V A tufted rug is produced by the apparatus and process as illustrated and described in relation to Figure 2 The carpet has the configuration illustrated and described in relation to Figure 3A. The production parameters are as follows: Thread Continuous nylon 6,6 looped pile thread of 542.5 g / m2 (16 ounces per square yard) Primary backing Non-woven polyester of 67.8 g / m2 (2 ounces per square yard) Pre-coating Latex SBR 474.5 g / m2 (16 ounces per square yard) loaded with 100 parts of CaC02 Fusing adhesive eenn ccaalliieennttee Modified polypropylene 1288.5 g / m2 (38 ounces per square yard) Laminated reinforcement Non-woven glass of 101.7 g / m2 (3 ounces per square yard) with acrylic binder. Polyurethane foam coverage 508.6 g / m2 (15 ounces per square yard) Urethane foam density .224 g / cc (14 pounds per cubic foot) Non-woven backing material (50% polypropylene, 50% polyester) 67.8 g / m2 (2 ounces per square yard), EXAMPLE VI A tufted rug is produced by the process apparatus as illustrated and described in relation to the Figure 5. The carpet has the configuration illustrated and described in relation to Figure 6A. The production parameters are as follows: Straight thread of nylon loop 6,6 hair of 508.6 g / m2 (15 ounces per square yard) white, 1350 deniers, non-folded, non-woven, non-thermo-fixed Primary backing Non-woven polyester of 135.6 g / m2 (4 ounces per square yard) Laminated reinforcement Non-woven glass of 101.7 g / m2 (3 ounces per square yard) with acrylic binder. Polyurethane foam coverage 508.6 g / m2 (15 ounces per square yard) Urethane foam density .256 g / cc (16 pounds per cubic foot) Nonwoven backing material (50% polypropylene, 50% polyester) 135.6 g / m2 (4 ounces per square yard) EXAMPLE VII A tufted carpet is produced by the apparatus and process as illustrated and described in relation to Figure 19. The carpet has the configuration illustrated and described in relation to Figure 18. The production parameters are as follows: Filament Continuous filament of the loop nylon 508.6 g / m2 (15 ounces per square yard) nylon 6,6 Primary backing Nonwoven polyester 135.6 g / m '(4 ounces per square yard) Pre-coating Latex SBR 542.5 g / m2 (16 ounces per square yard) loaded with 100 parts of CaC02 Reinforcing Material Non-woven glass of 67.8 g / m2 (2 ounces per square yard) with acrylic binder. Coverage of polyurethane foam 678.1 g / m2 (20 ounces per square yard.) Density of Urethane foam .256 g / cc (16 pounds per cubic foot) Comfort rating. 1. Gmax - Gmax simulates foot drop on a surface. The measure is reported as multiples of "g" (Gravities), or Gmax. The lower the value, the lower the force on impact, and the more comfort is perceived below the foot on the product. The higher the value, the higher the force before impact, and the less comfortable the carpet will feel. Test results Gmax ComfortPlusMR Milliken Standard cushion back cushion carpet mosaic - 116 Low weight cushion back cushion carpet mosaic of the present invention - 129 Standard commercial seamless carpets without subfloor - 185 Standard hard back carpet mosaic such as Everwher both described, a PVC stamp backing - 227 Resilience Rating Resilience and cushion - Resilience and cushion measures the bounce rate of a metal ball when dropped from a standard height. It shows the absorbing shock character of the cushion, which helps reduce visible wear on the surface of the carpet. The higher the value, the greater the rebound percent and the more resilient the cushion. Resilience Results Mattress mosaic with cushion backrest ComfortPlusMR Milliken Standard - 30 Low-weight cushion-backed carpet mosaic of the present invention - 27 Standard commercial broad carpets without sub-flooring - 17 Standard hard-backed carpet mosaic -13 Retention of Appearance Appearance retention qualification (ARR = Appearance Retention Rating) - the ARR value is determined by grading the carpet appearance change subject to exposure conditions in accordance with any of the ASTM D-5252 methods (Hexapod) or ASTM D-5417 (Vettermann) using the number of cycles for specified short and long term tests. ARR - Lightweight (short term > /=3.0, long term > /=2.5 ARR - Moderate (short term > /=3.5, long term > /=3.0 ARR - Heavy (short term > /=4.0, long term > /=3.5 The low weight modular carpet mosaic of the present invention had an APR of approximately 4.0 for the short term and 3.5 for the long term.

Durability The low weight polyurethane cushion carpet backing mosaic of the present invention is very durable and can withstand 25,000 cycles or more of the saddle test with no failures. According to at least one embodiment of the present invention, the primary carpet of low surface or frontal weight, preferably has a surface weight of less than 508.5 g / m2 (15 oz / yd2), and more preferably 406.8 g / m2 (12 oz / yd2) or less. The low weight carpet mosaic of the present invention is unexpectedly very salable and commercially viable due in part to its reduced cost, appearance, wear and cushion characteristics; sewing ability or union; monolithic pattern design; uniformity of appearance between mosaics; constant tone; durability; less broken; short hair; dense surface; and its combinations. A method employed to achieve sufficient yarn coverage, suitable for forming pattern and resilience in commercial use, in the carpet of low surface weight carpet of the present invention, uses a simple yarn with sufficient denier, in the range of lOOOd and 1400d in a non-thermofix form. When using non-thermofix yarn, the shrinkage that is carried out normally When thermosetting (typical approximately 11%), it is now carried out in the wet processing of the tufted carpeting. After application of dye, the carpet enters the steam applicator with continuous dye where the yarn bulges (shrinks approximately 11%) in the formed carpet fabric, thereby dramatically increasing the coverage of the carpet surface , reducing to the height of the hair and making a much denser surface fabric. The positive result of this shrinkage subsequent to fabric formation is better performance of the carpet with a low density surface weight, and improved aesthetic appearance due to the improved coverage. According to one embodiment of the present invention, it is preferred to have a hair height of less than .3175 cm (8/64") after dyeing (after heat setting) In accordance with at least one embodiment of the present invention, it is preferred to use an open cell foam such as a polyurethane foam and the foam or cushion backing.The lighter weight and reduced thickness of the tiles allow more tiles to be added in each box or each pallet.Also, each tile is more easy to handle during installation, easier to cut and easier to bend. There are at least four options or examples of the foam cushion to obtain commercially acceptable low weight foam products using polyurethane. 1) Use of polyurethane system with standard filling. A polyurethane foam contains 110 parts of filler and is applied at a low density of .24 g / cc (15 pounds / cubic foot) if the thickness is in the range of .1016 - .3048 cm (.04 -.12 in) and only the polymer weight is determined, using the previous density and fill levels, the polymer weight range would be 146.8 to 439.3 g / cc (4.32 to 12.96 oz / square yard). 2) A second option that also works would be to increase fill levels to 190 and reduce density to .208 g / cc (13 # / cubic foot). (Min that is possible with a filler system). At the same thickness limits, the polymer weights would then be 93.76 to 279.3 g / cc (2.72 - 8.24 oz / square yard). 3) A third option would be to use a polyurethane system without filler or filler (primary urethane). High densities such as the above are not possible with primary however, they perform due to the wall structure and the fact that no filler is present if we consider a primary of .096 g / cc (6 # / cubic foot) applied to thickness limits on the weight of polymer it would be 97.6 to 292.6 g / m2 (2.88 - 8.64 oz / sq. yd) 4) A fourth option is also possible. Textile rubber has an available polyurethane system called "Kangahide" that only has 15 parts of filler material and is applied at a density of .096 to .144 g / cc (6-9 lb / cu ft), if a calculation of Polymer back is made at the thickness limits described would be 145.8 to 441.4 g / m2 (4.3 - 13.02 oz / sq. yd). Although the above examples are concerned with polyurethane, a water-based foam system can also be used. Although printing the carpet composite is preferred and then cutting the tiles there, the carpet composite can be cut into tiles and then each cut tile can be printed. For example, preforms or cut tiles can be dyed by jet or printed by injection dye or dye. This provides improved registration of pattern or design in the mosaics and allows monolithic installation of complex designs.

In one embodiment, the invention relates to a single 1350d white carpet yarn, which is tufted into a backing. The surface or front weight is usually 406.9 g / m2 (12 ounces / yd2). The resulting surface fabric is weak, and has many "holes", where the backing is visible across the surface. The surface is applied to a cushion back by a resilient hot melt layer. The carpet passes through a Millitron broad carpet jet staining process, where the steam and dry heating involved in the dye fixation process shrink the tuft threads. The shrinkage results in short, dense plumes that are durable and look good. The roll is then cut in mosaic and shipped. According to at least one embodiment, the low weight cushion back rug of the present invention provides one or more of the following: Benefits 1. Reduced Cost 2. Comfort under the foot 3. Performance Reduced Cost 1. Less raw materials - lower hair height 2. lower processing cost - lower thread conversion to. Without heat setting b. without twisting c. Without folding 3. Less coloring a. Less quantity b. Wide and cut carpet printing c. Caliber 10 d. Coagulation chemistry - concentration of dye in the tip 4. Edge trimming is not required 5. Backup a. Different backing - polypropylene (woven) b. Nylon cap (for functionality) 6. Lower foam cost a. Thinner layer b. Increased range of speed reduction 7. 91.4 cm (36") mosaics (larger tiles) 8. More area can be run before cutting with doctor blade 9. Boarding / packing - from 80 to 110 tiles per pallet (Low thickness) / lightweight) 10. Installation to. You can use brick laying pattern (Many patterns) b. Easier to cut and detach because it is thinner Performance benefits. 1. Long duration a. Retention of appearance b. Retention of foam resilience c. Less susceptible to "detached lines" 2. With high pattern formation 3. Vacuum cleaner more easily 4. You can use an ashler pattern to place the tiles - less visible seams or joints 5. Performance a) Comfort under the foot b) Improved resilience / durability in high traffic areas c) Crush resistance d) Ergonomics e) Noise reduction f) Hidden imperfections under the carpet g) Reduced bearing resistance h) Cluck agglutination Of course It will be appreciated that while several potentially preferred modalities have been shown and described, the invention is in no way limited thereto, since modifications and other embodiments of the principles of this invention can be made that will occur to those skilled in the art to which this invention relates. Therefore, it is contemplated by the appended claims to cover any of these modifications and other embodiments that incorporate the features of this invention within the spirit and actual scope thereof.

Claims

CLAIMS 1.- A surface cover, wall covering, floor, carpet or carpet mosaic, comprising a primary carpet of low frontal or surface weight and a cushion layer. 2. - The surface cover, wall cover, floor, carpet or carpet mosaic as described in claim 1, characterized in that the low surface weight is less than or equal to approximately 508.6 g / m2 (15 oz / yd2) ). 3. - The surface cover, wall cover, floor, carpet or carpet mosaic as described in claim 1, characterized in that it also comprises an adhesive layer between the primary carpet and the cushion layer. 4. - The surface cover, wall cover, floor, carpet or carpet mosaic as described in claim 3, characterized in that the adhesive layer is less than or equal to approximately 1695.4 g / m2 (50 oz / yd2) . 5. The surface cover, wall cover, floor, carpet or carpet mosaic as described in claim 4, characterized in that the adhesive layer has approximately 1220.7 to 1695.4 g / m2 (36-50 oz / yd2). 6. - The surface cover, wall cover, floor, carpet or carpet mosaic as described in claim 3, characterized in that it also comprises a reinforcing material. 7. - The surface cover, wall cover, floor, carpet or carpet mosaic as described in claim 1, characterized in that the cushion layer has an approximate thickness of .1016 to .3048 cm (0.04 -0.12") 8. - The surface cover, wall cover, floor, carpet or carpet mosaic as described in claim 7, characterized in that the cushion layer has a thickness of approximately .1016 to .2286 cm (0.04 -0.09" ). 9. - The surface cover, wall cover, floor, carpet or carpet mosaic as described in claim 1, characterized in that the cushion layer has a polymer weight of less than about 508.6 g / m2 (15 oz / yd2) ). 10. The surface cover, wall cover, floor, carpet or carpet mosaic as described in claim 9, characterized in that the cushion layer has a polymer weight of about 146.5 to 439.4 g / m2 (4.32 - 12.96. oz / yd2). 11. - The surface covering, wall covering, floor, carpet or carpet mosaic as described in claim 10, characterized in that the cushion layer includes a polyurethane foam having approximately 110 parts of filler by weight. 12. The surface cover, wall cover, floor, carpet or carpet mosaic as described in claim 1, characterized in that the cushion layer has a polymer weight of approximately 92.2 to 279.4 g / m2 (2.72 - 8.24) oz / yd2). 13. The surface cover, wall cover, floor, carpet or carpet mosaic as described in claim 12, characterized in that the cushion layer includes a polyurethane foam with approximately 190 parts of filler by weight. 14. The surface cover, wall cover, floor, carpet or carpet mosaic as described in claim 1, characterized in that the cushion is an unfilled polyurethane. 15. The surface cover, wall cover, floor, carpet or carpet mosaic as described in claim 14, characterized in that the cushion layer has a density of approximately 0.96 g / cc (6 lbs./ per foot) cubic) and a polymer weight of approximately 97.7 to 292.9 g / m2 (2.88 - 8.64 oz / yd2). 16. - The surface cover, wall cover, floor, carpet or carpet mosaic as described in claim 1, characterized in that the cushion layer includes a lightweight cushion having a density of approximately 0.96 to .144 g / cc (6 to 9 lb / cu ft) 17. The surface covering, wall covering, floor, carpet or carpet mosaic as described in claim 1, characterized in that the light weight cushion is a polyurethane system with approximately 15 parts of filler material and a polymer weight of approximately 145.8 to 441.5 g / m2 (4.30 -13.02 oz / yd2). 18. The surface cover, wall cover, floor, carpet or carpet mosaic as described in claim 1, characterized in that the cushion layer includes at least one of polyurethane foam and water-based foam system. 19. The surface cover, wall cover, floor, carpet or carpet mosaic as described in claim 1, characterized in that the cushion layer includes a light weight cushion having a density of .256 g / cc ( 16 lb / cubic foot). 20.- The surface cover, wall cover, floor, carpet or carpet mosaic as shown described in claim 1, characterized in that it has resilience and low foot comfort. 21. The surface cover, wall cover, floor, carpet or carpet mosaic as described in claim 1, characterized in that it exhibits performance characteristics that qualify it for heavy commercial use. 22. The surface cover, wall cover, floor, carpet or carpet mosaic as described in claim 1, characterized in that it also comprises a reinforcement material embedded in the cushion layer. 23. The surface cover, wall cover, floor, carpet or carpet mosaic as described in claim 22, characterized in that the cushion layer has a thickness of approximately .1016 a .3048 cm (0.04 - 0.12") 24. The surface cover, wall cover, floor, carpet or carpet mosaic as described in claim 1, characterized in that the carpet of low surface weight is at least one of crenellated and agglomerated 25 .- The surface cover, wall cover, floor, carpet or carpet mosaic as described in claim 1, characterized in that the Low surface weight carpet is aesthetically pleasing. 26.- The surface cover, wall cover, floor, carpet or carpet mosaic as described in claim 1, characterized in that the carpet of low surface weight is made of threads of 1,000 to 1,700 deniers. 27.- The surface cover, wall cover, floor, carpet or carpet mosaic as described in claim 1, characterized in that the cushion layer includes a foam layer of .224 to .288 g / cc (14 - 18 lbs. Per cubic foot) of density. 28.- The surface cover, wall cover, floor, carpet or carpet mosaic as described in claim 1, characterized in that the carpet of low surface weight is made using a simple wire without thermofix. 29.- The surface covering, wall cover, floor, carpet or carpet mosaic as described in claim 28, characterized in that the single yarn has a denier of approximately 1000 a 1400. 30.- The surface cover, wall cover, floor, carpet or carpet mosaic as described in claim 29, characterized in that the Low weight carpet has a non-woven backing and a latex coating. 31.- The surface cover, wall cover, floor, carpet or carpet mosaic as described in claim 1, characterized in that the carpet of low surface weight has a surface weight of less than 678.1 g / m2 (20 oz / yd2). ) and dye by jet. 32.- A carpet mosaic with cushion backrest with low weight, comprising a primary carpet with low surface weight and a low weight cushion backrest. 33. The carpet mosaic according to claim 32, characterized in that the low surface weight is less than or equal to approximately 508.6 g / m2 (15 oz / yd2). 34. - The carpet mosaic according to claim 32, characterized in that it also comprises a layer of adhesive between the carpet and the cushion back. 35. The carpet mosaic according to claim 34, characterized in that the adhesive layer has approximately 1221 to 1695 g / m2 (36-50 oz / yd2). 36.- The carpet mosaic according to claim 32, characterized in that it has resilience and comfort under the foot. 37. - The carpet mosaic according to claim 32, characterized in that it exhibits performance characteristics that qualify it for heavy commercial use. 38. The carpet mosaic according to claim 34, characterized in that it also comprises a reinforcing material in or between at least one of the primary carpet, lightweight adhesive and cushion layer. 39.- The carpet mosaic according to claim 32, characterized in that the light weight cushion has an approximate thickness of .1016 to .3048 cm (0.04 - 0.12"). 40.- The carpet mosaic according to claim 32, characterized in that the lightweight cushion has a thickness approximate of .1016 to .2286 cm (0.04 -0.09"). 41. The carpet mosaic according to claim 32, characterized in that the lightweight cushion has a polymer weight of less than 508.6 g / m2 (15 oz / yd2). 42. - The carpet mosaic according to claim 32, characterized in that the light weight cushion has a polymer weight of about 146.5 to 439.4 g / m2 (4.32 - 12.96 oz / yd2). 43. - The carpet mosaic according to claim 32, characterized in that the lightweight cushion is a polyurethane foam having approximately 110 parts of filler by weight. 44. - The carpet mosaic according to claim 32, characterized in that the light weight cushion has a polymer weight of approximately 92.2 to 279.4 g / m2 (2.72 - 8.24 oz / yd2). 45. The carpet mosaic according to claim 32, characterized in that the lightweight cushion is a polyurethane foam having approximately 190 parts of filler by weight. 46. The carpet mosaic according to claim 32, characterized in that the lightweight cushion is a polyurethane without filler. 47. The carpet mosaic according to claim 32, characterized in that the light weight cushion has a density of approximately 97.7 to 292.9 g / m2 (2.88 - 8.64 oz / yd2) and a polymer weight of approximately 97.7 to 292.9 48. The carpet mosaic according to claim 32, characterized in that the light weight cushion has a density of approximately 0.96 to 0.144 g / cc (6 a). 9 lb / cu ft). Lightweight has a density of approximately .096 to .144 g / cc (6 to 9 lb / cu ft). 49. The carpet mosaic according to claim 32, characterized in that the lightweight cushion is a polyurethane system of approximately 15 parts of filler material by weight and a polymer weight of approximately 145.8 to 441.5 g / m2 ( 4.30 - 13.02 oz / yd2). 50. - The carpet mosaic according to claim 32, characterized in that the lightweight cushion is at least one of polyurethane foam and a water-based foam system. 51. The carpet mosaic according to claim 32, characterized in that the lightweight cushion has a density of approximately .256 g / cc (16 lb. / cubic foot). 52. - The carpet mosaic according to claim 32, characterized in that the carpet of low surface weight is at least one of tufted and agglomerated. 53. - The carpet mosaic according to claim 32, characterized in that the carpet of low surface weight is aesthetically pleasing. 54. - The carpet mosaic according to claim 32, characterized in that the carpet under Surface weight is made from a denier thread of approximately 1,000 to 1,700. 55. The carpet mosaic according to claim 32, characterized in that the low weight cushion has a density of approximately 2,224 to .288 g / cc (14-18 lbs. Per cubic foot). 56. - The carpet mosaic according to claim 32, characterized in that the carpet of low surface weight is made using a single wire without thermofixing. 57,. The carpet mosaic according to claim 56, characterized in that the single yarn has a denier of about 1,000 to 1,400. 58. - The carpet mosaic according to claim 32, characterized in that the carpet of low surface weight has a woven backing and a latex coating. 59. The carpet mosaic according to claim 32, characterized in that the carpet of low surface weight has a surface weight of less than 678.1 g / m2 (20 oz / yd2) and is dyed by a jet. 60.- A carpet compound with a low weight cushion back, comprising a low weight primary carpet and a thin cushion backrest. 61. The carpet composite according to claim 60, characterized in that the low weight carpet has a surface weight less than or equal to approximately 508.6 g / m2 (15 oz / yd2). 62. - The carpet composite according to claim 60, characterized in that the thin cushion backing has a thickness of approximately .1016 to .3048 cm (0.04 - 0.12"). 63. - The carpet composite in accordance with claim 60, characterized in that the thin cushion has an approximate thickness of .1016 to .2286 cm (0.04 -0.09"). 64. - The carpet composite according to claim 60, characterized in that the thin cushion has a polymer weight less than 65. The carpet composite according to claim 60, characterized in that the thin cushion has a polymer weight of approximately 146.5 to 439.4 g / m2 (4.32 - 12.96 oz / l). and d2) 66. The carpet composite according to claim 60, characterized in that the thin cushion is a polyurethane foam having approximately 110 parts of filler by weight. 67. - The carpet composite according to claim 60, characterized in that the thin cushion has a polymer weight of approximately 92.22 to 279.4 g / m2 (2.72 - 8.24 oz / yd2). 68.- The carpet composite according to claim 60, characterized in that the thin cushion is a polyurethane foam with approximately 190 parts of filler by weight. 69. The carpet composite according to claim 60, characterized in that the thin cushion is a polyurethane without filler. 70. - The carpet composite according to claim 60, characterized in that the thin cushion has a density of about .096 g / cc (6 lbs./ per cubic foot) and a polymer weight of about 97.7 to 292.9 g / m2 (2.88 - 8.64 oz / yd2). 71. The carpet composite according to claim 60, characterized in that the thin cushion has a density of about 0.96 to 144. g / cc (6 to 9 lb / cu ft). 72. The carpet composite according to claim 60, characterized in that the thin cushion is a polyurethane system, with approximately 15 parts of the filling material by weight and a polymer weight of approximately 145.8 to 441.5 g / m2 (4.30). - 13.02 oz / yd2). 73. - The carpet composite according to claim 70, characterized in that the thin cushion is at least one of a polyurethane foam and a water-based foam system. 74. - The carpet composite according to claim 60, characterized in that the thin cushion bag has a density of .256 g / cc (16 lb. / cubic foot). 75. - The carpet composite according to claim 60, characterized in that it also comprises a layer of adhesive between the primary carpet and the thin cushion backrest. 76. - The carpet composite according to claim 75, characterized in that the adhesive layer is less than or equal to about 1695.4 g / m2 (50 oz / yd2). 77. The carpet composite according to claim 75, characterized in that it also comprises a reinforcement material on or between at least one of the carpet, the adhesive layer and the thin cushion bag. 78. - The carpet composite according to claim 60, characterized in that it exhibits performance characteristics that qualify it for heavy commercial use. 79. - The carpet composite according to claim 60, characterized in that it has resilience and comfort under the foot. 80. The carpet composite according to claim 60, characterized in that the composite is adapted to be cut at least one of carpet, carpet mosaic, continuous carpets or runners, area rugs, mats and the like. 81. The carpet composite according to claim 75, characterized in that it exhibits performance characteristics that qualify it for heavy commercial use and has resilience and comfort under the foot. 82. - The carpet composite according to claim 77, characterized in that it exhibits performance characteristics that qualify it for heavy commercial use and has resilience and comfort under the foot. 83. - The carpet composite according to claim 60, characterized in that the low weight carpet is at least one of interlaced and agglomerated carpet. 84. - The carpet composite according to claim 60, characterized in that the low weight carpet is aesthetically pleasing. 85. The carpet composite according to claim 60, characterized in that the low weight carpet is made of a yarn having a denier of about 1,000 to 1,700. 86.- The carpet composite according to claim 60, characterized in that the low weight cushion has a density of approximately 2,224 to .288 g / cc (14-18 lbs. Per cubic foot). 87.- The carpet composite according to claim 60, characterized in that the low weight carpet is made using a simple wire without thermofixing. 88. The carpet composite according to claim 87, characterized in that the single yarn has a denier of about 1,000 to 1,400. 89. The carpet composite according to claim 60, characterized in that the low weight carpet has a non-woven backing and a latex coating. 90. The carpet composite according to claim 60, characterized in that the low weight carpet has a surface weight of less than 678.1 g / m2 (20 oz / yd2) and is jet-dyed. 91.- A carpet mosaic with a low weight cushion, comprising a primary carpet of low weight, a thin cushion backrest and a hot melt layer, between the primary carpet and the thin cushion backrest. 92. The carpet composite according to claim 90, characterized in that the carpet mosaic includes a reinforcing material in or between at least one of the primary carpet, the hot melt layer and a thin cushion backing. 93.- A low weight carpet mosaic, comprising a layered structure of a low weight primary carpet precursor, latex pre-coating adhesive, hot melt adhesive, fiberglass, polyurethane foam and felt. 94.- A low weight modular carpet mosaic, comprising a primary carpet of low surface weight, a hot melt layer including a reinforcing material and a thin cushion layer having a non-woven backing. 95.- A low weight modular carpet mosaic, comprising a layered structure comprising a primary carpet of low surface weight, latex pre-coating adhesive, hot melt adhesive, glass fiber, polyurethane foam and felt. 96.- A carpet mosaic of low weight, comprising a layered structure of a carpet primary low weight, hot melt adhesive, polyurethane foam and felt. 97.- A low-weight modular carpet mosaic, comprising a layer structure of a low weight primary carpet, hot melt adhesive, glass fiber and polyurethane foam. 98.- A low-weight modular carpet mosaic, comprising a layer structure of a low weight primary carpet, hot melt adhesive and polyurethane foam. 99.- A low weight modular carpet mosaic, comprising a layered structure of a low weight primary carpet, bitumen hot melt layer, fiberglass, polyurethane foam and felt. 100.- A carpet mosaic of low weight, comprising a layered structure of a low weight primary carpet, a first layer of hot melt adhesive, fiberglass, a second layer of hot melt adhesive, polyurethane foam and felt. 101.- A low-weight modular carpet mosaic, comprising a layered structure of a low weight primary carpet, a first layer of hot melt adhesive, fiberglass, a second layer of hot melt adhesive, polyurethane foam and felt. 102.- A low weight modular carpet mosaic, comprising a layer structure of a low weight primary carpet precursor, fiberglass, latex pre-coating adhesive, hot melt adhesive, polyurethane foam and felt. 103.- Method for forming a low-weight modular carpet mosaic, comprising the steps of: adhesively bonding a layer of glass reinforcing material to the base of a low weight primary carpet fabric having a surface weight less than equal to about 508.6 g / m2 (15 oz / yd2) to form a laminate, place a layer of wet polyurethane foam forming composition in direct contact with a layer of non-woven backing material to form a layer of polyurethane foam with thickness of approximately .1016 to .3048 cm (0.04 - 0.12"), joining the polyurethane foam layer with the glass reinforcement material to form a modular composite of low weight carpet and cutting carpet mosaics from the carpet composite 104. Method according to claim 103, characterized in that the step of bonding the glass reinforcement layer to the base of the fabric in an adhesive manner. of primary carpet uses a hot melt layer of approximately 1220.7 to 1695.4 g / m2 ((36 - 50 oz / yd2) 105.- The method to form a low weight modular carpet composite, comprising the steps of: joining in adhesive form a layer of glass reinforcing material with the base of a low weight primary carpet fabric to form a laminated composite, and placing a layer of wet polyurethane forming composition, in direct contact relation with the glass reinforcing material, in a way to provide a layer of polyurethane foam with thickness of approximately .1016 to .3048 cm (0.04 -0.12) ") 106. Method according to claim 105, characterized in that the adhesive bond of the glass reinforcement material with the base of the primary carpet fabric forms a hot melt layer of approximately 1220.7 to 1695.4 g / m2 (36 -50 oz / yd2) 107.- Procedure for the formation of a floor carpet mosaic, whereby the mosaic produced is suitable for disposition as discrete modular units through a floor surface, the procedure is characterized in that it comprises the steps of: applying a layer of latex pre-coating adhesive to the backing of a light weight primary carpet fabric, applying a hot melt adhesive over the latex coating, forming a layer of polyurethane foam on at least one of a woven or non-woven backing material, and bonding the polyurethane foam to the hot melt adhesive to form a modular, light weight carpet composite, and cutting Carpet composite carpet mosaics. 108. A method according to claim 107, characterized in that the primary carpet of low weight has a surface weight less than or equal to approximately 508.6 g / m2 (15 oz / yd2), the polyurethane foam layer has a thickness of approximately .1016 to .3048 cm (0.04 - 0.12"), and the hot melt layer is approximately .1220.7 to 1695.4 g / m2 (36 -50 oz / yd2) .109.- A method in accordance with the claim 107, characterized in that it further comprises the step of adding a reinforcing material between the hot melt adhesive and the polyurethane foam 110.- A low weight carpet mosaic produced by the process of claim 103. 111.- Composite of low weight carpet produced by the process of claim 105. 112. - Floor carpet mosaic produced by the process of claim 107. 113. - Floor carpet mosaic produced by the method of claim 109. 114. - A surface covering such as a wall cover, panel cover, floor, floor covering, carpet, carpet mosaic or the like, comprising: a material of low surface weight and a cushion backrest. 115. The cover according to claim 114, characterized in that the material of the upper and lower surface, and the cushion back is connected to the lower surface of the material. 116. - The cover according to claim 114, characterized in that it is a cover for floor. 117. The cover according to claim 114, characterized in that the cushion back is of low weight. 118.- The cover according to claim 114, characterized in that the material is a pile material. 119. The cover according to claim 114, characterized in that the low surface weight is less than about 678.1 g / m2 (20 oz / yd2). 120. - The cover according to claim 114, characterized in that the low surface weight is less than or equal to approximately 508.6 g / m2 (15 oz / yd2). 121. The cover according to claim 114, characterized in that the low surface weight is less than or equal to about 406.9 g / m2 (12 oz / yd2). 122. - The cover according to claim 114, characterized in that the material has an upper surface having at least one of design, pattern, color and combination thereof. 123. - The cover according to claim 122, characterized in that the design, color, pattern and combination thereof are made by at least one of injection dyeing, printing jet dyeing, and combinations thereof. 124. The cover according to claim 114, characterized in that the material is a tufted pile material made from a thread having a less than one twist. 125. The cover according to claim 114, characterized in that the material is a tufted pile material, made of at least one of natural and synthetic yarn. 126. - The cover according to claim 114, characterized in that the material is at least a portion of a wide carpet material of tufted hair. 127.- The cover according to claim 114, characterized in that the wide tufted pile carpet material has a top hair face having at least one of design, color or pattern and its combinations. 128.- The cover according to claim 127, characterized in that at least one of the design, color, pattern and combinations thereof are made by at least one injection dyeing, dyed by jet, printing and combinations in wide carpets. 129.- The cover according to claim 114, characterized in that the cover has a hexapod rating of at least 3. 130.- The cover according to claim 114, characterized in that the cover has resilience and comfort under the foot. 131. The cover according to claim 114, characterized in that the cover has a Gmax test that is less than 130. 132. - The cover according to claim 114, characterized in that the cover has a resilience rating greater than 25. 133. - The cover according to claim 114, characterized in that the cover exhibits performance characteristics that qualify it for heavy commercial use. . 134. - The cover according to claim 114, characterized in that the cover has an appearance retention rating (ARR). Appearance Retention Rating) of at least 3.5 in the long term and at least 4.0 in the short term. 135. The cover according to claim 114, characterized in that the cover has a hexapod color change test result of only light or moderate color change. 136. The cover according to claim 114, characterized in that the cover has a result of height retention of hexapod hair of at least 74%. 137. The cover according to claim 114, characterized in that the cover has an intermediate layer between the material and the cushion back. 138. - The cover according to claim 137, characterized in that the intermediate layer is a resilient layer made of glass fiber material and hot melt. 139.- A surface covering such as floor material, floor covering, carpet, carpet mosaic or the like, comprising: a material of low surface weight having a surface weight of less than about 678.1 g / m2 (20 oz / yd2) ), and a cushion backrest. 140.- Surface covering such as floor material, floor covering, carpet, carpet mosaic or the like, comprising: a material of low surface weight having a surface weight of less than about 678.1 g / m2 (20 oz / yd2) ), a cushion backing and a hexapod rating of at least 3. 141. A surface covering such as floor material, floor covering, carpet, carpet mosaic or the like, comprising: a material of low surface weight having a surface weight of less than about 678.1 g / m2 (20 oz / yd2), and a cushion back and resilience and comfort under the foot. 142. - A surface covering such as flooring material, floor covering, carpet, carpet mosaic or the like, comprising: a base material surface weight having a surface weight of less than about 678.1 g / m2 (20 oz / yd2), a cushion backing, and a Gmax test result of less than 130. 143. - A surface covering such as floor material, cover for floor, carpet, carpet mosaic or the like, comprising: a material of low surface weight having a surface weight of less than about 678.1 g / m2 (20 oz / yd2), a cushion backing, and a resilience rating greater than 25. 144. - A surface covering such as floor material, floor covering, carpet, carpet mosaic or the like, comprising: a material of low surface weight having a surface weight of less than about 678.1 g / m2 (20 oz. / yd2), a cushion back, and an ARR Appearance Retention Rating of at least 3.5 in the long term and at least 4.0 in the short term. 145. A surface covering such as floor material, floor covering, carpet, carpet mosaic or the like, comprising: a material of low surface weight having a surface weight of less than about 678.1 g / m2 (20 oz / yd2) ), a cushion layer, and a hexapod color change test result of only light to moderate color change. 146. - A surface covering such as floor material, floor covering, carpet, carpet mosaic or the like, comprising: a material of low surface weight having a surface weight of less than about 678.1 g / m2 (20 oz / yd2), a cushion backing, and a hair height retention result in hexapod test of a hair height retention of at least about 74%. 147.- A surface cover such as floor material, cover for floor, carpet, carpet mosaic or the like, comprising: a material of low surface weight having a surface weight of less than about 678.1 g / m2 (20 oz / yd2), a cushion back, and an intermediate layer between the material and the cushion backrest. 148.- The cover according to claim 147, characterized in that the intermediate layer is a resilient layer made of hot melt and reinforcement material. 149. A surface covering such as floor material, floor covering, carpet, carpet mosaic, or the like, comprising: a material of low surface weight having a surface weight of less than about 678.1 g / m2 (20 oz. and d2), a cushion backing, and a reinforcement material in at least one of the material, the cushion backrest and between the material and the cushion backrest. 150. A material for floor, floor covering, floor covering, carpet, carpet mosaic, or the like, comprising: a material of low surface weight, an intermediate layer and a cushion backing. 151. Floor material according to claim 150, characterized in that it has a good bonding capacity. 152. - Floor material according to claim 150, characterized in that it has a monolithic pattern design. 153. - Floor material according to claim 150, characterized in that it has uniformity of appearance between tiles. 154. - Floor material according to claim 150, characterized in that it has a single mosaic constant of the same batch of dye. 155. Floor material according to claim 150, characterized in that it has at least one of durability, low crush damage, short hair, dense surface and combinations thereof. 156. - Method for marketing carpets to carpet customers, comprising the steps of offering the customer at least one of each carpet mosaic With standard cushion backing, carpet mosaics with low weight cushion backing and hard backed carpet mosaics to meet all your carpet needs and thus replace wide carpet. 157.- Method for marketing carpet mosaic as a replacement for wide carpet, which includes the steps of offering a carpet mosaic with low weight cushion backing for sale at the same price as wide installed carpet cost. 158. - Substrate for a carpet with jet staining pattern, characterized in that it comprises a low weight pile material adapted to be jet-dyed, and a low weight cushion backing. 159. Substrate according to claim 158, characterized in that it also comprises a layer of adhesive between the hair material and the cushion back. 160. Substrate according to claim 159, characterized in that it also comprises a reinforcement material in or between at least one of the hair material, the adhesive layer and the back of the cushion. 161. Substrate according to claim 158, characterized in that the hair material is thermoset after dyeing.