US20090031870A1 - System and method for cutting a web to provide a covering - Google Patents
System and method for cutting a web to provide a covering Download PDFInfo
- Publication number
- US20090031870A1 US20090031870A1 US12/181,498 US18149808A US2009031870A1 US 20090031870 A1 US20090031870 A1 US 20090031870A1 US 18149808 A US18149808 A US 18149808A US 2009031870 A1 US2009031870 A1 US 2009031870A1
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- US
- United States
- Prior art keywords
- web
- recited
- fabric
- cutting
- adhesive
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
- B25B—TOOLS OR BENCH DEVICES NOT OTHERWISE PROVIDED FOR, FOR FASTENING, CONNECTING, DISENGAGING OR HOLDING
- B25B11/00—Work holders not covered by any preceding group in the subclass, e.g. magnetic work holders, vacuum work holders
- B25B11/005—Vacuum work holders
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/08—Devices involving relative movement between laser beam and workpiece
- B23K26/083—Devices involving movement of the workpiece in at least one axial direction
- B23K26/0838—Devices involving movement of the workpiece in at least one axial direction by using an endless conveyor belt
- B23K26/0846—Devices involving movement of the workpiece in at least one axial direction by using an endless conveyor belt for moving elongated workpieces longitudinally, e.g. wire or strip material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B26—HAND CUTTING TOOLS; CUTTING; SEVERING
- B26F—PERFORATING; PUNCHING; CUTTING-OUT; STAMPING-OUT; SEVERING BY MEANS OTHER THAN CUTTING
- B26F3/00—Severing by means other than cutting; Apparatus therefor
- B26F3/06—Severing by using heat
- B26F3/16—Severing by using heat by radiation
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K2103/00—Materials to be soldered, welded or cut
- B23K2103/30—Organic material
- B23K2103/38—Fabrics, fibrous materials
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K2103/00—Materials to be soldered, welded or cut
- B23K2103/50—Inorganic material, e.g. metals, not provided for in B23K2103/02 – B23K2103/26
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B26—HAND CUTTING TOOLS; CUTTING; SEVERING
- B26D—CUTTING; DETAILS COMMON TO MACHINES FOR PERFORATING, PUNCHING, CUTTING-OUT, STAMPING-OUT OR SEVERING
- B26D7/00—Details of apparatus for cutting, cutting-out, stamping-out, punching, perforating, or severing by means other than cutting
- B26D7/01—Means for holding or positioning work
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B26—HAND CUTTING TOOLS; CUTTING; SEVERING
- B26D—CUTTING; DETAILS COMMON TO MACHINES FOR PERFORATING, PUNCHING, CUTTING-OUT, STAMPING-OUT OR SEVERING
- B26D7/00—Details of apparatus for cutting, cutting-out, stamping-out, punching, perforating, or severing by means other than cutting
- B26D7/20—Cutting beds
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
- Y10T156/10—Methods of surface bonding and/or assembly therefor
- Y10T156/1052—Methods of surface bonding and/or assembly therefor with cutting, punching, tearing or severing
- Y10T156/1084—Methods of surface bonding and/or assembly therefor with cutting, punching, tearing or severing of continuous or running length bonded web
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
- Y10T156/12—Surface bonding means and/or assembly means with cutting, punching, piercing, severing or tearing
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/14—Layer or component removable to expose adhesive
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/14—Layer or component removable to expose adhesive
- Y10T428/1476—Release layer
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T83/00—Cutting
- Y10T83/04—Processes
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T83/00—Cutting
- Y10T83/748—With work immobilizer
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T83/00—Cutting
- Y10T83/869—Means to drive or to guide tool
- Y10T83/8773—Bevel or miter cut
Abstract
A covering is provided for exterior or interior application on solid surfaces such as garage floors, patios, and walkways. The covering is formed as tiles formed of a top layer of fibrous material, such as carpet, and a bottom layer of adhesive applied in spaced bands, lines, strips or rows that allow the tile to be removed from the surface after installation if desired. A release sheet, preferably formed of plural pieces, is secured over the adhesive for removal during installation. A portion of the release sheet can function as a positioning strip to assist in accurately placing the tiles. The covering is manufactured by coating the bottom surface of a strip of material in beads of adhesive, smoothing the beads into bands, lines, strips or rows, and then cutting the strip into tiles using a non-mechanical cutter such as a laser.
Description
- This patent application is related to provisional patent application Ser. No. 60/953,519 filed Aug. 2, 2007, to which Applicant claims the benefit of the earlier filing date. That application is incorporated herein by reference and made a part hereof.
- 1. Field of the Invention
- This invention relates to surface coverings for exterior or interior use. In particular, this invention relates to fibrous coverings suitable for use on solid surfaces, particularly on concrete, such as garage floors, patios or walkways.
- 2. Description of the Related Art
- It is known to provide coverings, such as indoor/outdoor carpet, on walkways or patios to provide traction on potentially slippery surfaces and to cover unsightly surfaces. Due to the difficulty in affixing coverings to exterior surfaces that are irregular and exposed to the elements, most coverings are merely laid over the surface or tacked in place. However, this does not provide a secure covering and can slip or easily become displaced.
- There has been an interest in designing garages that are more organized, attractive and comfortable in recent years. Typically, a garage floor is formed of concrete, which is difficult to keep clean, particularly dust free. Concrete is also a very hard and unforgiving surface to stand or work on. The problems with covering a garage floor involve providing a surface that can withstand typical uses, particularly vehicular traffic. Coverings merely laid over concrete cannot be driven on without bunching and slipping.
- In the past, coverings were manufactured with a backing to which an adhesive or a double-sided adhesive tape was applied. Typically, the adhesive was applied to the entire backing, especially for very demanding traffic applications. The covering was then applied to a surface, such as a garage floor. It was extremely difficult to remove the covering from the surface, if, for example, the covering was damaged or otherwise needed to be removed.
- Another problem with prior art coverings is that during installation, it was necessary to orient the coverings in a predetermined pattern or orientation. Some coverings had a release liner that covered the adhesive and the release liner had arrows or other indicia to assist the installer with installing the tile in the correct orientation. Unfortunately, even with such indicia, after the tiles are turned fabric side up the indicia cannot be seen and/or the orientation of the indicia gets lost relative to the tiles that are already situated on the surface that causes misplaced tiles or coverings. Unfortunately, because of the bond between the adhesive and the tiles, such tiles were difficult to remove and prolong the installation time.
- Still another problem with prior art systems is that the covering was cut with contact cutters that did not provide for accurate cutting of the edges. Consequently, when such coverings were placed into a surface adjacent other coverings, they could not be properly fit and/or if fit would not look proper.
- There is, therefore, a need for a system and method for making a covering product that is suitable for exterior or interior use, and particularly suitable for use in a garage that is subject to vehicular traffic and can withstand high loads and traction forces while remaining in place. There is also a need for providing a covering that is easy to install and maintain or repair if necessary.
- Aspects of embodiments of the invention relate to a product that provides a durable covering for exterior and interior surfaces.
- Another aspect of embodiments of the invention relates to a product that is easy to install and remains securely fastened to an underlying surface.
- An additional aspect of embodiments of the invention relates to product that may be easily replaced and maintained.
- This invention is directed to fibrous covering for outdoor or indoor use having an adhesive coating on the underside for adhesion to a surface, which can be a solid surface, such as a concrete patio, walkway, driveway or garage floor. It is contemplated that this covering can be applied to most solid surfaces, also including wood.
- Aspects of the invention are directed to a covering to be installed on a surface, comprising a fibrous layer having a top fibrous surface, a bottom surface and a plurality of edges, an adhesive layer applied to the bottom surface of the fibrous layer, and a release sheet removably secured to the adhesive layer. The adhesive layer is formed in spaced bands, lines, strips or rows across the bottom surface. The release sheet includes at least one main sheet and a positioning sheet overlapping the main sheet for removal prior to the main sheet to expose only a portion of the adhesive layer. In one embodiment illustrated in
FIGS. 1-7 , the main sheet includes an overhanging edge that is folded over the edge of the fibrous layer and onto the top fibrous surface. - The invention is further directed to the covering in the form of a tile with a plurality of tiles assembled directly adjacent to each other.
- The folded edge can be secured with a tab to the fibrous layer. The tab can include indicia for installing the tile in a particular orientation.
- Aspects of the invention are also directed to a method of installing a covering on a surface comprising providing a plurality of pieces of covering, each piece formed as a tile made of a fibrous layer having a top fibrous surface, a bottom surface and a plurality of edges. An adhesive layer is applied to the bottom surface of the fibrous layer, wherein the adhesive layer is formed in spaced bands, lines, strips or rows across the bottom surface. A release sheet is removably secured to the adhesive layer, wherein the release sheet includes at least one main sheet and a positioning sheet overlapping the main sheet, wherein the main sheet includes an overhanging edge carrying positioning indicia that is folded over the edge of the fibrous layer and onto the top fibrous surface. The method includes positioning one of the tiles at a determined location on the surface using the positioning indicia on the folded edge of the main sheet, removing the positioning sheet to expose only a portion of the adhesive layer and tacking the tile at the desired location, and removing the main sheet to adhere the tile in the determined location. In accordance with the method, another tile is positioned at a determined location directly adjacent to the first tile, the positioning sheet of the second tile is removed to expose only a portion of the adhesive layer and tacking the tile at the desired location, and the main sheet is removed to adhere the tile in the determined location next to the first tile.
- Other aspects of the invention are directed to a method of manufacturing a covering for installation on a surface comprising providing a strip of fibrous material having a top fibrous surface, a bottom surface and opposed edges, applying adhesive in an intermittent or spaced-apart pattern, spaced beads or strips on the bottom surface of the strip, applying a release sheet over the adhesive on the bottom surface of the strip, and separating the strip with the adhesive and release sheet thereon by a non-mechanical mechanism into individual pieces.
- In one aspect, this invention comprises a system of manufacturing a covering for installation on a surface, the system comprising at least one web handler for driving a web of fibers to a cutting station, an air table adapted to provide air pressure to facilitate movement and positioning the web at the cutting station, and a cutter located at the cutting station for cutting the web of fibers into the covering having a predetermined shape.
- In still another aspect, this invention comprises method for cutting a covering or tile comprising the steps of positioning a web of fabric at a cutting station using an air table having a working surface and a plurality of apertures for providing a cushion of air, and cutting the web of fabric with a cutter to provide the covering or tile having a predetermined shape.
- Separating the strip into pieces can include cutting the strip with a laser.
- The method can further comprise the step of providing a roll of fibrous material and slitting the roll into the strip.
- Applying the adhesive in an intermittent pattern can include applying rows of beads or strips of adhesive. The adhesive beads or strips can be pressed into the bottom surface to form the beads or strips into bands, lines, strips or rows. Applying the release sheet can include pressing the release sheet onto the bottom surface and thereby pressing the beads or strips of adhesive into the bottom surface and forming the beads or strips into bands, lines, strips or rows.
- A further object of the invention is to provide a system and method that accurately cuts coverings or tiles by providing a non-contact cutter that will accurately cut edges within tighter tolerances than what could be achieved with contact cutters.
- Another object is to provide a system and method for providing indicia that facilitates installing the covering or tile.
- Still another object is to provide a system and method for applying an adhesive directly to fabric, without any backing or liner.
- Yet another object is to provide a system, method and tile that achieves one or more of the objects or advantages described herein.
- These and other objects and advantages of the invention will be apparent from the following description, the accompanying drawings and the appended claims.
- The invention will now be described in conjunction with the accompanying drawings in which:
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FIG. 1 is a top view of a plurality of carpet pieces in accordance with the invention installed on a surface; -
FIG. 2 is a bottom view of one of the carpet pieces ofFIG. 1 before installation; -
FIG. 3 is a top view of the carpet piece ofFIG. 2 ; -
FIG. 4 is an enlarged side view in cross section of a carpet piece installed on a surface; -
FIG. 5 is a bottom view of a carpet piece during manufacture; -
FIG. 6 is a bottom view of a carpet piece during manufacture at a later stage than seen inFIG. 5 ; -
FIG. 7 is a schematic view of a manufacturing process for making the carpet pieces in accordance with the invention; -
FIG. 8A is an isometric view of a system and method for making a covering or tile in accordance with one embodiment; -
FIG. 8B is an enlarged sectional view taken alongline 8B-8B ofFIG. 8A ; -
FIG. 8C is an enlarged sectional view similar to 8B, taken along theline 8C-8C of 8A, showing various details of a web after an adhesive and liner has been applied; -
FIG. 9 is a fragmentary elevation view of an adhesive application and roller; -
FIGS. 10 , 11 and 12 are enlarged fragmentary elevation views showing diverging cuts and joining of adjacent coverings or tiles; -
FIGS. 13 and 14 are isometric views showing a system and means for attaching the tile to a surface; -
FIG. 15A is a fragmentary perspective view illustrating at least one removable label having an indicia for indicating a nap or pattern in the covering or tile; -
FIGS. 15B-18 are isometric views of alternative arrangements of coverings or tiles in accordance with various embodiments of the invention; -
FIGS. 19A-19H are various illustrations showing an operation of the process and system in accordance with another embodiment of the invention; -
FIG. 19I is a cross-sectional view, taken along the line 19I-19I inFIG. 19C showing various details of a cutting table and cutting aperture; -
FIG. 20 is a perspective view of another embodiment of the invention; -
FIGS. 21A-21H are various views illustrating the method and system for cutting in accordance with the embodiment illustrated inFIG. 20 ; -
FIG. 22 is a view of an end of an air table used in the embodiment illustrated inFIG. 20 illustrating the sensors and air cushion on which the web moves over a surface of the air table; -
FIG. 23 is a sectional view taken along the line 23-23 inFIG. 21A ; and -
FIG. 24 is a fragmentary enlarged view of thearea 24 inFIG. 21A illustrating an adjustable guide and notched out portion for permitting a laser to move past the guides. - In the drawings, like reference numerals indicate corresponding parts in the different figures.
- This invention is directed to a surface covering in the form of tiles, particularly suited for covering a solid exterior surface, such as a garage floor, an exterior environment, an environment subject to exposure to the elements, or an environment subject to heavy traffic and high loads. The invention is particularly suited for covering large expanses of exterior solid surfaces or surfaces subject to the elements or harsh conditions. The invention can also be used for covering other types of surfaces including, for example basement floors, factory floors, walkways or patios.
- The tiles in accordance with the invention are particularly suited for connection to surfaces formed of concrete. Such surfaces can range from smooth to finished depending on the finish technique and wear. The invention may also be used on other exterior surfaces including concrete, synthetic composites, wooden boards, and plastic or plastic composite boards.
- Referring to
FIG. 1 , the covering in this form of the invention includes a plurality of carpet pieces ortiles 10 that are applied to a surface S to form a solid covering. Eachcarpet piece 10 is formed as a tile that can be affixed to an underlying surface. The tile may be any size or shape. In one preferred configuration, the tiles are square for easy installation and measure about 12 inches by 12 inches, 18 inches by 18 inches, 24 inches by 24 inches, 36 inches by 36 inches, or 48 inches by 48 inches. -
Carpet piece 10 has a top layer orsurface 12 preferably made of a fibrous material, such as carpet material, which provides a surface with good traction and appearance. The fibrous material can be manufactured in various forms, with one particularly desirable form forming a ribbed surface. A desirable weight of fibers would fall within the range 18-60 ounces per square yard. One useful weight for exterior high traffic areas is 28 ounces per square yard. A good range for durability is 22-40 ounces per square yard. It is preferred that the weight and form of thecarpet surface 12 be resistant to compression and denting to avoid damage from parked vehicles, for example. - Preferably, the carpet material could be formed from any suitable material that can receive an adhesive and that can be cut subsequently with a non-contact cutter as described herein. Such material could be wool, nylon, polymer or other materials suitable for accommodating a traffic surface, such as a walking or rolling traffic surface and may be dispersed or combined with polypropylene carpet fibers. The dispersal of these fibers results in a firmer, more stable structure. Due to the improved structure, it is not necessary to use a backing, such as latex as is commonly used, but such backing could be used with the invention described herein. One problem with latex backings in a wet environment is that the foaming agent used during manufacturing becomes reactivated when wet, which causes the material to become slippery. If desired, UV treated fibers may be included in the mix to provide protection to the
carpet piece 10 in installations exposed to sunlight. Of course, other materials may be used depending on the particular application, including for example polyester or other blends. - The underside of the
top layer 12 forms a bottom layer orsurface 14, which has adhesive applied directly thereto with no intermediate foam layer, as is common with interior use carpeting. Directly coating the adhesive onto thebottom surface 14 of the fibrous material forms an integral structure that adds to the durability. If it is desired to add an intermediate layer, to form a liquid barrier for example, an incompressible layer can be disposed over thebottom surface 14 of the fibrous layer. - The adhesive is applied to form narrow adhesive bands, lines, strips or
rows 16, as seen inFIGS. 4 and 6 . The process for forming theband 16 is described below. The adhesive bands, lines, strips orrows 16 are spaced across the entire width of thecarpet piece 10 with free areas of thebottom surface 14 between eachband 16. The adhesive bands, lines, strips orrows 16 allow thecarpet piece 10 to be removed from the surface S when desired while still maintaining a secure connection to the surface. Preferably less than half, and most preferably about 25-30%, of the surface area of thebottom surface 14 is coated with the adhesive bands, lines, strips orrows 16. As seen inFIG. 4 , the spaced bands, lines, strips orrows 16 form a discontinuous connection between thecarpet piece 10 and the surface S, which allows the bond to be broken more easily when pulled free from the surface for repair or replacement. - The
adhesive band 16 is preferably made of a removable adhesive (PSA) that is a hot melt, meaning it is applied at 100% solids. Suitable adhesive compositions are available from many different manufacturers and can be used as a hot melt adhesive. It may be desirable to use anadhesive band 16 that is water insoluble to resist deterioration due to the elements. - The viscosity of the
adhesive band 16 may also be varied to affect penetration or wetting into the back surface of the fibrous layer. Lowering the viscosity, increases the wet-ability (tack) of the adhesive, thereby allowing it to penetrate deeper into thebottom surface 14. As would be appreciated by those of ordinary skill with adhesives, the viscosity of the adhesive will affect the coating weight. - The
bottom surface 14 with the adhesive bands, lines, strips orrows 16 is covered by arelease sheet 20 that is removable upon installation. Referring toFIG. 2 , therelease sheet 20 is preferably formed as plural sheets, including, for example, twomain sheets 22 and a positioning sheet orstrip 24. Themain sheets 22 are installed on thebottom surface 14 with a gap between, shown by the dashed lines inFIG. 2 . Thepositioning sheet 24 is installed over the gap to overlap themain sheets 22. During installation, thepositioning sheet 24 can be removed first to expose adhesive in the gap between themain sheets 22 to locate and tack thetile 10 in place prior to final placement. Of course, thesheets - Preferably, the
main sheets 22 each have anedge 26 that extends outwardly from opposed sides of thetile 10. Theedges 26 function as a gripping flange during installation for easy removal of the release sheet when thetile 10 is in the proper position. Theedges 26 are folded over onto thefibrous surface 12, as seen inFIG. 3 for convenient packaging and easy access. Theedges 26 can be secured by atab 28 that also carriesindicia 30 regarding the nap and/or instructions for installation. For example, theindicia 30 can indicate the direction of the pile so that thetiles 10 can be placed in an alternating configuration or an aligned configuration. Samples of both patterns are shown inFIG. 1 . If desired, other portions of the release sheet can carry instructions or indicia, especially thepositioning strip 24. - The
release sheet 20 is removed during installation and discarded. Therelease sheet 20, which is also called a release liner, can be formed of any releasable sheet material that is easily pulled from thebottom surface 14. A suitable material is silicone coated polyester film or silicon coated paper. A preferred material is a silicone coated polyester sheet about ½-2 mils (0.0005 inch to 0.002 inch) thick. The important features of therelease sheet 20 are that it releases reliably from the adhesive surface and avoids tearing so that it is easy for an installer to use, and it has the thermal stability to tolerate temperatures in the 300 degree Fahrenheit range. - The
carpet pieces 10 can be installed on a surface S using the following procedure. First, the center of the surface S is located and marked with alignment marks such as two perpendicular lines or simply a straight edge. Then, the first tile is placed at the center mark. Thepositioning strip 24 is removed, and thecarpet piece 10 is tacked in the desired position. Theindicia 30 on thetabs 28 is used to properly orient thecarpet piece 10. When the position is finally determined, thetabs 28 are released, and themain sheets 22 are removed by lifting each side of thecarpet piece 10 leaving the center portion tacked in place. Eachsubsequent carpet piece 10 is installed in the same manner using the adhered carpet piece orcarpet pieces 10 as a guide. Theindicia 30 can be used to form a pattern as desired. It is also possible to form or print a pattern or design in or on thetop surface 12 of the fibrous material, which can be repeated or pieced together during installation. - Due to the intermittent application of
adhesive band 16, the connection between thecarpet piece 10 and the surface S can be broken by applying an upward force to thecarpet piece 10. By this,carpet pieces 10 may be selectively replaced. This provides for a longer life to the overall covering since damaged orworn pieces 10 may be replaced when necessary while leaving the remainder of the covering in tact. On the other hand, since theadhesive band 16 spans the entire width of thebottom surface 14, thecarpet piece 10 is securely bonded to the surface S and resists shifting or bunching when a load is applied. For example, it is possible to drive a vehicle over the covering with no adverse affects. - Referring to
FIG. 7 , a technique for manufacturing thecarpet pieces 10 is explained. The fibrous material is typically provided in amill roll 40. Themill roll 40 is slit intostrips 42, using a slitter or other conventional slitting mechanism, having the desired width for eachcarpet piece 10. Astrip 42 is then fed with thebottom surface 14 facing up to an adhesive applyingstation 44 where in this illustration beads, rows or strips 46 of adhesive are deposited in a pattern of rows or lines across the width of thebottom surface 14. As illustrated relative to the embodiment shown inFIGS. 8A-15B , the preferred embodiment applies the adhesive in strips, lines or rows of adhesive, not beads, that become flattened and pressed into the web as described later herein. This is shown inFIG. 6 . - The application techniques can vary depending on the particular adhesive composition, but one effective method is for the adhesive to be extruded and, if desired, treated with pressure and/or vacuum to enhance physical penetration of the fibrous
bottom layer 14. Other suitable methods known to those of ordinary skill in the art are also possible, such as spraying, extrusion, or other methods of coating. It is preferred that hydrophobic adhesive be used to prevent water contaminating the bond between the adhesive and underlying surface. - At the
next station 48, therelease sheet 20 is applied to thebottom surface 14 to cover the adhesive beads or strips 46. Therelease sheet 20 is pressed onto thebottom surface 14, thereby flattening the beads or strips 46 and forming the bands, lines, strips orrows 16 of adhesive. This is shown inFIG. 6 . This operation presses the adhesive into thebottom surface 14, which creates a stronger connection with the fibrous material, and causes the beads or strips to blend into bands, lines, strips orrows 16, which provides more secure adhesion to surface S during installation. - Application of the
release sheet 20 is shown in a simplified form for purposes of explanation, but would include several nip rolls for applying eachmain sheet 22 and the overlappingpositioning sheet 24. Therelease sheet 20 is pressed onto thebottom surface 14 with theedges 26 overhanging the edges of thestrip 42. It is also possible to use multiple stations to press the adhesive beads or strips 46 into the surface and then apply therelease sheet 20. - The
strip 42 now carrying the adhesive bands, lines, strips orrows 16 and therelease sheet 20 is fed to a separatingstation 50 where thestrip 42 is separated intoindividual pieces 10. Due to theadhesive band 16 and therelease sheet 20 formed into a composite strip, it is not possible to use a mechanical cutting mechanism to effectively and precisely separate thecarpet pieces 10. In accordance with this invention, a transverse cut is made through the entirecomposite strip 42 by using non-mechanical means, such as a laser. It would also be possible to use other non-mechanical means, such as a water jet. The laser, in this case, provides an accurate and neat transverse cut to separate thestrip 42 intocarpet pieces 10. - In the embodiment illustrated in
FIGS. 1-7 , the overhanging edges 26 are then folded over thetop surface 12 and attached with thetabs 28. It is also possible to merely crease theedges 26 so that they remain overlapped onto thetop surface 12 without use oftabs 28 or even to leave them extending outwardly from the edges. - When packaged, it is preferred that the
carpet pieces 10 are also alternated so that the sides of thetiles 10 that do not have the releasesheet overlapping edge 26 are not aligned within a stack. As these sides have exposed adhesive edges it is desirable to space them apart with the release sheet edges 26 to avoid inadvertent sticking betweenstacked tiles 10. - Referring now to
FIGS. 8A-19I , another embodiment of the invention is shown. This embodiment is also directed to a surface covering or overlay in the form of tiles, particularly suited for covering a solid surface, such as a floor, garage floor, patio, an exterior or interior environment, an environment subject to exposure to elements or an environment subject to heavy traffic and high loads, such as airports, retail stores and the like. This embodiment is particularly suited for covering large expanses of exterior or interior solid surfaces or surfaces subject to the elements, or harsh conditions. The invention can also be used for covering other types of surfaces including, but not limited to, basement floors, factory or retail floors, common areas, public areas, walkways or patios as mentioned earlier. - The tiles in accordance with this embodiment are particularly suited for connection to surfaces formed of concrete. Such surfaces must be smooth or finished. The embodiment may also be used on other exterior surfaces including concrete, synthetic composites, wood boards and plastic or plastic composite boards or any other suitable flat surface.
- A key feature of this embodiment is that the coverings or tiles are manufactured in accordance with a system and method that provides an adhesive that is pressed directly into the surface of the fibers or the backing. In the embodiment being described herein, it should be understood that the fibrous layer is not supported with a backing or coating, but rather has an adhesive, described below, applied directly to the fibers and pressed therein relating to needle-punched products. It should be understood that the adhesive described herein is selected to provide a desired amount of bond between the covering and the surface area to be covered so that if it is desired to remove the covering from the surface it can be done by hand or with a simple tool, such as a pair of pliers. If desired, UV treated fibers may be included in the mix of fibers to make the covering or tile to provide protection to the covering or tile in installations exposed to sunlight. Of course, other materials may be used depending on the particular application, including for example polyester or other blends.
- Referring now to
FIG. 8A , asystem 100 is provided for making a plurality of coverings ortiles 102, which in the illustration being described have a predetermined shape, such as square or substantially square, although it should be understood that the covering ortile 102 may be any size or shape. In one illustrative configuration, the covering or tile shape is square for easy installation and measure 18 inches by 18 inches, 12 inches by 12 inches, 24 inches by 24 inches, 48 inches by 48 inches, or 96 inches by 96 inches, but could be bigger or smaller if desired. - As with the embodiment described earlier herein, the carpet material that makes up the
web 104 is formed from any suitable material that can receive an adhesive and that can be cut with a non-contact cutter as described herein. Such material could be wool, nylon, polyester, polypropylene or other materials suitable for accommodating a traffic surface, such as a walking or rolling traffic surface. The dispersion of these fibers results in a firmer, more stable structure. As mentioned earlier, it is not necessary to use a backing, such as latex as is commonly used in the past, but one could be used if desired. Of course, other materials may be used depending upon the particular application, including, for example, polyester or other blends. - Referring back to
FIG. 8A , notice that theweb 104 comprises the first ortop surface 108 and a second orbottom surface 110. Thesystem 100 comprises an application station 112 (FIGS. 8A and 9 ) comprising anadhesive applicator 114 that applies an adhesive 116 directly to thebottom surface 110 in strips, bands, rows orlines 116 a. The invention may be used with anunbacked web 104 or with a web (not shown) that has an intermediate layer, backing or the like. In the embodiment being described, theweb 104 is supported during non-contact cutting of the covering ortile 102, so no backing or support material on theweb 104 is necessary to perform the cutting. As mentioned later herein, the system and method permit non-contact cutting of theweb 104 after the adhesive 116 is applied, which cannot be done as efficiently or accurately with traditional contact cutters, such as cutters that used a knife, blade, die or jig. - As illustrated in
FIG. 9 , note that theadhesive applicator 114 applies adhesive 116 in strips, bands, rows orlines 116 a directly to thebottom surface 110 of theweb 104, which causes the adhesive 116 to form an integral structure with the fibrous material of theweb 104 that adds to durability. Theadhesive applicator 114 applies the adhesive 116 in strips, bands, rows orlines 116 a that get pressed and “flattened” into flattened strips, lines, rows orbands 116 a. It should also be understood that the bond between the fibrous material and the adhesive 116 is greater than the bond between the adhesive 116 and a surface 120 (FIG. 14 ) on which the covering ortile 102 is adhered or mounted, so that when the covering ortile 102 is pulled from thesurface 120 inFIGS. 14 and 15B the bond between the adhesive 116 and thesurface 120 will give way prior to the bond between the fibrous material and the adhesive 116. This facilitates removing the covering ortiles 102 after installation in a manner that causes a majority of the adhesive to be removed when the covering ortile 102 is removed from thesurface 120. - If it is desired to add an intermediate layer (for example, to form a liquid barrier), an incompressible layer can be disposed over the
bottom surface 110 of the fibrous layer orweb 104. - Referring back to
FIG. 8A , notice that the adhesive 116 is applied to thebottom surface 110 at theapplication station 112 in strips, lines, rows or bands that get pressed into flattened bands, lines, strips orrows 116 a as they exit apressing station 115 as shown. As with the embodiment described earlier, the adhesive bands, lines, strips orrows 116 a are spaced across the width of the covering ortile 102 and across thebottom surface 110 of theweb 104, with open or free areas 122 (FIG. 14 ) between the adhesive bands, lines, strips orrows 116 a. The adhesive is not applied completely to the edge so that during cutting, the non-contact cutters do not have to cut through the adhesive. It should be understood that after the covering ortile 102 is situated on thesurface 120, the areas between the adhesive bands, lines, strips orrows 116 a and thesurface 120 andarea 122 defines achannel 124 which may facilitate directing fluid flow if desired. - As mentioned earlier, the adhesive bands, lines, strips or
rows 116 a allow the covering ortile 102 to be removed from thesurface 120 when desired while maintaining a secure connection to thesurface 120. Preferably, less than half and most preferably about 25-30% of the surface area of thebottom surface 110 is coated with the adhesive bands, lines, strips orrows 116 a. Any amount of adhesive could be used to meet the demands of different applications. As with the embodiment described earlier, the spaced adhesive bands, lines, strips orrows 116 a form a discontinuous connection between the covering ortile 102 and thesurface 120, which, again, allows the bond to break more easily when the covering or tile is pulled from the surface for repair or replacement. - As with the embodiment described earlier, the adhesive 116 is preferably made of a removable pressure sensitive adhesive (PSA) that is a hot melt, meaning it is applied at 100% solids. Suitable adhesive compositions are available from many different manufacturers and can be used as a hot melt adhesive. The viscosity of the adhesive 116 may also be varied to affect penetration or wetting into the
bottom surface 110 of thefibrous web 104. As would be appreciated by those of ordinary skill with adhesives, the viscosity of the adhesive will affect the coating weight. - The
pressing station 115 comprises a plurality of niprollers bottom surface 110. As illustrated inFIG. 8C , notice that the adhesive 116 is pressed into thebottom surface 110 and extends beyond a first plane P1 a predetermined distance. In the illustration being described, the predetermined distance may be at least ten-thousandth of an inch, and this may vary depending on the web material used. Moreover, the adhesive 116 may be applied at a basis weight of 50-200 gsm. - Note that the thickness D2 of the adhesive above the
bottom surface 110 in plane P1 will typically be less than the distance D1 for a non-tufted material or application unsupported by web. For applications where the fibrous material is supported by a backing, the distance D1 will typically impregnate the backing to the top surface of the backing. In such an application, the distance D2 may be greater than the distance D1. Accordingly, it should be understood that the degree of adhesive penetration is largely dependent upon the porosity of theweb 104 and the viscosity of the adhesive 116. - When the adhesive 116 is placed in adhesive bands, lines, strips or
rows 116 a on thebottom surface 110, it comprises a first, pre-pressed width W1 (FIG. 8B ). After the adhesive bands, lines, strips orrows 116 a are pressed into thebottom surface 110, the adhesive bands, lines, strips orrows 116 a comprise a second width W2 (FIG. 8C ), which is wider than the first width W1. In the illustration being described, the second width is less than one-quarter of an inch, but both widths W1 and W2 could be larger or smaller if desired. Thus, it should be understood that after the adhesive bands, lines, strips orrows 116 a are pressed into thebottom surface 110 they become wider which provides more adhesive surface area for the adhesive 116 to bond to the surface 120 (FIGS. 14 and 15B ). - Referring back to
FIG. 8A , notice that at least one or a plurality of release liners, rolls orsheets pressing station 115, as illustrated inFIGS. 8A and 9 . Thebottom surface 110 with the adhesive bands, lines, strips orrows 116 a is covered by the sheets 130-134 that are removable upon installation. As illustrated inFIGS. 8A and 9 and similar to the embodiment described earlier, a release sheet (FIGS. 13 and 14 ) is preferably provided or formed as one or from the plurality of sheets 130-134, including, for example, twomain sheets positioning sheet 134. Themain sheets bottom surface 110 with a gap between them that exposes at least one or a part of one of the adhesive bands, lines, strips orrows 116 a as illustrated inFIG. 13 . Thepositioning sheet 134 is installed over the gap to overlap themain sheets FIGS. 13 and 14 . During installation, thepositioning sheet 134 can be removed to expose a strip of adhesive bands, lines, strips orrows 116 a in the gap between themain sheets tile 102 in place prior to final placement. After the covering ortile 102 is finally placed in position, themain sheets tile 102 is secured in place. As alluded to earlier, therelease sheets rows 116 a. - The
release liners surface 120. A suitable material is silicone coated polyester film of the type described earlier herein with the previous embodiment. It is desirable to userelease liners release sheets - Referring back to
FIG. 8A , notice that thesystem 100 further comprises atransfer station 140 comprising a plurality ofrollers feed roller driver 154 that causes theweb 104 to be moved through thesystem 100. As illustrated inFIG. 8A , thefeed roller driver 154 is coupled to aroller controller 156 that in turn is coupled tovarious sensors 158. Thesensors 158 are also coupled to aprogrammable controller 160 as shown. In the illustration being described, thefeed roller driver 154 is programmable and drives theroller 150 to drive the web 104 a predetermined distance, which depends on the dimension of the covering or tile 102 being cut. For example, for an 18 inch by 18 inch square tile, thefeed roller driver 154 drives theroller 150 to drive theweb 104 in increments of approximately 18.25 inches. - The
system 100 further comprises a cutting station 159 that has a cutting table orsupport 200 for supporting theweb 104 during cutting at the cutting station 159. The cutting station 159 further comprises at least one or a plurality of drivable or moveable lasers ornon-contact cutters drivers 170 that are mounted to a frame or support (not shown for ease of illustration) that supports thenon-contact cutters support 200 as shown. - Notice that the table or
support 200 comprises a generallyplanar surface 202 that is supported by a plurality oflegs 204. Thesurface 202 comprises a cutting aperture or opening 206 (FIGS. 8A , 19A and 19I) that generally corresponds to the predetermined shape to be cut into theweb 104 for defining the covering ortile 102. Although the illustration shown shows the predetermined shape of the covering ortile 102, and consequently the cuttingaperture 206, being generally square, it should be understood that the predetermined shape could be any desired shape. - The table or
support 200 also comprises a second planar member or platen 208 (FIG. 19A ) having a bottom surface 208 a that is generally coplanar with thesurface 202 to support the covering ortile 102 after it has been cut from theweb 104. Note that a pan or reservoir 210 (FIGS. 8A , 19A-19H) is secured by conventional means, such as by a weld or with fasteners, to the underside 200 a of the table orsupport 200. A pedestal support 212 (FIG. 19I ) is secured to abottom surface 210 a of the pan orreservoir 210 and to a bottom surface 208 a of the secondplanar member 208 to support the secondplanar member 208 in the position shown. - An exhaust conduit or
tube 214 couples the pan orreservoir 210 to anexhaust fan 216 for exhausting air and gases resulting from the non-contact cutting from the pan orreservoir 210 to atmosphere. - The laser or non-contact cutters 162-168 are coupled to and under the control of the programmable controller 160 (
FIG. 19A ). During cutting as described later herein, theprogrammable controller 160 causes the non-contact cutters 162-168 to generatelaser beams 162 a-168 a to cut through theweb 104, while theweb 104 is in a resting position at the cutting station 159, to provide the covering ortile 102. In the illustration being described, the laser or non-contact cutters 162-168 are 180 Watt lasers manufactured by Coherent, Inc. of Santa Clara, Calif. Although not shown for ease of illustration, the laser or non-contact cutters 162-168 are mounted on a track, frame or gantry and the lasers 162-168 and thelaser drivers 170 may comprise the laser system available from Kern Electronics & Lasers, Inc. of Wadena Minn. Moreover, as is known in the laser art, one or more mirrors (not shown) may be provided to facilitate adjustment of the laser beam to the optics lens. Notice that during cutting, thelaser beams 162 a-168 a are received in the cuttingaperture 206 in the table 200. Theprogrammable controller 160 energizes thelaser drivers 170 to drive the lasers 162-168 to cut the predetermined shape or pattern, and during such cutting, thelaser beams 162 a-168 a are continuously received in the cuttingaperture 206. Applicants have found that the cuttingaperture 206 facilitates reducing or eliminating reflection of thelaser beams 162 a-168 a as can occur if there is a reflective surface underneath theweb 104 and in line with thelaser beams 162 a-168 a. The cuttingaperture 206, therefore, facilitates providing a clean cut ofedges FIG. 8A ) in theweb 104 to provide the covering ortile 102. Further description of the system and process for cutting are provided later herein relative toFIGS. 19A-19I . - Advantageously, the non-contact cutting system utilizing at least one non-contact cutter, such as one or more of the
moveable lasers edges 102 b-102 e. - The operation of the
system 100 and method will be described relative toFIGS. 8A andFIGS. 19A-19I , which are simplified for ease of illustration. During operation, theprogrammable controller 160 and theroller controller 156 energizes the at least one or a plurality offeed roller drivers 154 to move theweb 104 through thesystem 100 until an end 104 b reaches a desired location (FIGS. 8A and 19B ). Thesensors 158 sense the position of the end 104 b and of the lasers or non-contact cutters 162-168 and provide this information to theprogrammable controller 160 and theroller controller 156. When the end 104 b reaches the desired position, at least one or a plurality offeed roller drivers 154 cause the at least one roller 142-152 to cease moving theweb 104. At least a portion of theweb 104 is now positioned at a cutting station 159, as illustrated inFIGS. 8A and 19B . Notice that theweb 104 is not cut or held in place by mechanical means that would cause distortion or displacement, and theweb 104 lies and rests generally flat at the cutting station 159. Because theweb 104 is not being distorted or displaced during cutting, theweb 104 can be cut very accurately and within tight tolerances. - After the
web 104 is in the desired position at the cutting station 159 (FIG. 8A and 19B ), theprogrammable controller 160 energizes aplate driver 174 to drive aplate 172 into engagement with the top surface 108 (FIG. 19A ) and to hold theweb 104 against aplaten 208. Theplate 172 engages thetop surface 108 and gently secures theweb 104 against theplaten 208 during cutting as shown. It should be appreciated that theplate 172 holds theweb 104 substantially flat during cutting; however, theplate 172 does not apply enough pressure on theweb 104 to cause distortion or displacement of the material making up theweb 104 while theweb 104 is being held or cut. This facilitates accurately cutting theweb 104 within tight tolerances. Next, theprogrammable controller 160 energizes thelaser drivers 170 and the lasers or non-contact cutters 162-168 to cut into thetop surface 108 of theweb 104 in the desired predetermined shape or pattern. In the illustration being described, the predetermined shape of the covering ortile 102 is a square. - In the illustration being described, it should be understood that each of the
edges FIGS. 8A and 19E ) of the covering ortile 102 are cut with the laser beams of the 162 a, 164 a, 166 a and 168 a (FIG. 19C ), respectively, of the lasers or non-contact cutters 162-168. As mentioned earlier, thelaser beams 162 a-168 a are received in the cuttingaperture 206 during cutting, and the exhaust fan 216 (FIG. 19A ) exhausts any smoke or debris through thetube 214 to the atmosphere. - In the illustration being described, the lasers or non-contact cutters 162-168 are laser cutters, but they could be other types of non-contact cutters, such as water jets or the like. By non-contact cutting as described herein, there is no mechanical contact between the cutter and the
web 104, as opposed to a traditional mechanical cut with a knife or blade. In the past, cutting a web with adhesive was difficult because the adhesive would contaminate the blade or knife. Thus, it should be understood that each of theedges 102 b-102 e defines a non-contact cut that were laser-cut by the lasers ornon-contact cutters laser driver 170 drives the lasers or non-contact cutters 162-168 in a direction indicated by the arrows inFIGS. 8A and 19C , and thelaser beams 162 a-168 a cut edges 102 b-102 e as the lasers or non-contact cutters 162-168 are driven by thelaser drivers 170 over thebottom surface 110. Note in the illustration being described that the plurality ofedges 102 b-102 e define substantially a 90 degree angle with respect to any adjacent edge and in the illustration in the being described, is cut within a tolerance of less than five-thousandths of an inch. - As previously mentioned, the
web 104 is cut in a relaxed state, without tension, pressure, pulling, deformation or distortion of the web during cutting or the use of backing, which facilitates achieving a very accurate desired cut. The system and method enables the cutting of aweb 104 that does not have a backing, but that does have apre-applied adhesive 116 and release liner(s) 130-134. As mentioned earlier, this is difficult to do with contact cutters, such as a knife or blade, because of the tendency for the adhesive to stick to and contaminate the knife or blade. - As described herein, the system and method provide the non-contact cutter means and method that facilitates cutting any desired size and shape because the size and shape are not bound by the limitations of traditional mechanical cutting knives, blades, dies and jigs required with traditional contact cutters of the past. In the past, the displacement of the web that occurred as a result of the cutting, knives, blades, dies and jigs used during contact cutting had to be accounted for in the final cut product because of cupping and curling problems encountered while the material was being held and/or cut. Advantageously, the embodiments described herein utilize at least one non-contact cutter, such as the moveable lasers 162-168, that eliminates the need to use the dies, jigs and contact cutters, like knives and blades, that caused pressure on the web or that resulted in undesired displacement of the material during the cut. As illustrated and described herein, the system and method utilize at least one non-contact cutter, 162-168, and no knives, blades, jigs or dies on the
web 104 to apply a cutting pressure on theweb 104 during cutting. This reduces or eliminates displacement of the material making up theweb 104, which in turn provides coverings ortiles 102 that can be cut within tight tolerances. - Notice as illustrated in
FIGS. 10-12 , that each of the non-contact cuts diverge (as viewed in cross section) away from a cutting plane or line 171 (FIG. 10 ). This provides a beveled undercut as illustrated inFIG. 11 . Although not shown, at least one of the lasers 162-168 could be positioned at a desired angle relative to theweb 104 to create the angled or beveled cut.FIG. 10 shows the laser ornon-contact cutter 168 generating thelaser beam 168 a that cuts thetop surface 108. As thelaser beams bottom surface 110 and toward thetop surface 108, thelaser beams cutting line 171 to provide anedge top surface 108 or thebottom surface 110. Thus, it should be understood that each laser cut through theweb 104 diffuses or diverges away from thecutting line 171 as the cut extends away from cuttingplane 171 as it extends from thetop surface 108 toward thebottom surface 110 when viewed in cross section. Each of theedges edges cutting line 171. - Referring to
FIGS. 11 and 12 , the inventor has found that the diverging cut mentioned earlier along theedges 102 b-102 e provides a very tight seam between adjacent coverings ortiles 102 when the separate covering ortile 102 are placed adjacent each other during installation, as illustrated inFIGS. 11 and 12 . The fibrous materials at the edges, such as 102 c and 102 e, engage each other and the fibers at the edges become bunched and/or compressed to provide the tight seam as shown inFIG. 12 . This facilitates providing a tiling system that provides a “tight” seam between adjacent coverings ortiles 102 if desired. - Returning to the illustration in FIGS. 8A and 19A-19H, after the lasers or non-contact cutters 162-168 are finished cutting the covering or
tile 102, theprogrammable controller 160 ceases energizing the lasers or non-contact cutters 162-168 and causes thelaser drivers 170 to cease moving them. Theprogrammable controller 160 then energizes theplate driver 174 to raise the plate 172 (FIG. 19D ). Theroller controller 156 energizes thefeed roller drivers 154 to drive, advance or increment the web 104 (FIG. 19E ) so that the next covering or tile 102 can be cut, as illustrated inFIGS. 19F-19H ). - Notice that the
cut edge 180 c 1 (19H) ofscrap piece 180 c drives theedge 102 e of the previously cut covering ortile 102 toward a storingstation 182 where the coverings ortiles 102 are stacked for storing or packing. When the next covering ortile 102 is to be cut (FIG. 19E ), theroller controller 156 energizes thefeed roller drivers 154 to increment theweb 104 so that another covering or tile 102 can be cut. After theweb 104 is incremented, theplate 172 is then caused to engage the web 104 (FIG. 19F ).Programmable controller 160 energizes thelaser drivers 170 to drive the lasers or non-contact cutters 162-168 (FIG. 19F ) in the direction (i.e., back to their previous position) opposite that indicated by the arrow shown inFIGS. 8A and 19C . Accordingly, it should be understood that thelaser drivers 170 move or drive the lasers or non-contact cutters 162-168 back and forth in one linear plane in the illustration being described to cut the plurality of coverings ortiles 102. After cutting, theplate 172 is again raised (FIG. 19G ) and theweb 104 is again advanced (FIG. 19H ) so that the next covering or tile 102 can be cut. The process repeats until the desired number of coverings ortiles 102 are cut. - It is to be noted that during each cutting, the lasers or non-contact cutters 162-168 cut slightly beyond each adjacent edge in order to provide a clean and accurate cut. In this regard, the
moveable lasers web 104 and beyond theedges edges moveable lasers FIG. 19A ) of theweb 104. Note that the side scrap pieces (that is, the scrap pieces 180 a and 180 b (FIG. 19A ) resulting from the cut ofedges individual scrap piece 180 is created as well. In this regard, notice that thescrap piece 180 c has anedge 180 c 1 corresponding to the cut ofedge 102 e by laser beam 164 a, anedge 180 c 2 corresponding to the cut ofedge 102 c bylaser beam 166 a, and edges 180 c 3 and 180 c 4 created bymoveable lasers scrap piece 180 c either falls from the cut covering ortile 102 by gravity after it clears anend 202 b of the table orsurface 202, or thescrap piece 180 c may remain with the cut covering ortile 102 because of the adhesive 116. If the piece remains, an operator may simply pull the piece off and discard or recycle it. - It should also be understood that the
system 100 could use a single high-speed laser cutter that could effectively cut all edges, such as the four edges in the illustration, if desired. Alternatively, a plurality of laser cutters, such as the plurality of lasers or non-contact cutters 162-168, or some smaller or larger number of laser cutters may be used if desired. - Advantageously, the inventor has found that by using the lasers or non-contact cutters 162-168 to cut the
edges 102 b-102 d, very tight tolerances in cuts and shapes of cuts can be achieved. By cutting all theedges 102 b-102 e with at least one or a plurality of non-contact cutters, such as with a laser, tighter tolerances than the past can be achieved and theweb 104 can be cut after the adhesive is applied. In the illustration, a square is cut within a tolerance of five-thousandths of an inch. Also, notice that theweb 104 is cut after the adhesive 116 and release liner(s) 130-134 is applied, and the system and method cut all three simultaneously as shown and described. - Referring back to
FIG. 8A , thesystem 100 may further comprise a removablelabel applying station 184 for applying a removable label 186 (FIGS. 8A and 15A ) to thetop surface 108 of the covering or tile 102 as best illustrated inFIG. 15A . Notice that theremovable label 186 comprises afirst side 186 a and asecond side 186 b. A portion of thesecond side 186 b may have a removable adhesive and also a portion or area of thesecond side 186 b may have no removable adhesive to facilitate grabbing and removing theremovable label 186 from thetop surface 108. - Importantly, notice that the
first side 186 a comprises an indicia, such as an arrow, that provides an indication of the direction of the nap of the fibers that make up theweb 104. Although in the embodiment being described, the at least oneremovable label 186 may indicate a direction of the nap, they may also be placed to indicate a pattern, an opposite direction or some other direction that may facilitate installation of a plurality of coverings ortiles 102 onto thesurface 120. In some installations, it may be desired or necessary to arrange the coverings ortiles 102 in a predetermined order or pattern to have a design pattern (not shown) or nap of the coverings ortiles 102 facing the same direction, as illustrated inFIG. 16 , situated in the direction illustration inFIG. 17 , situated in opposite directions as shown inFIG. 18 , or perhaps in a perpendicular direction as shown inFIG. 15A . An important point is that at least oneremovable label 186 provides indicia for the user to use while installing a plurality of the coverings ortiles 102 onto thesurface 120 which facilitates quick and proper installation in a predetermined or desired pattern. It has been found that having the at least oneremovable label 186 situated on thetop surface 108 of each covering ortile 102 provides quick and easy means or indicia for the installer to correctly position and orient the covering ortile 102. - After the at least one of
removable label 186 is situated on thetop surface 108 of each covering ortile 102, thescrap piece 180 c may be removed (FIG. 19H ) from the covering ortile 102 if it remains therewith. The covering ortile 102 may be packaged for distribution or further processing. An inventory of, for example, five or more coverings ortiles 102 may be situated in a box or other packaging, as described earlier, and shipped for further processing, distribution or sale. - Contrary to the embodiment described earlier herein relative to the embodiment shown In
FIGS. 1-7 , notice that the coverings ortiles 102 are provided in cleanly cut squares, without any overhangingrelease liners FIGS. 8A-19I , therelease liners edges release liners edges non-contact cutters web 104, unlike the embodiment described relative toFIGS. 1-7 which utilizedindicia 30 on thetabs 28 for proper orientation of the covering ortile 102. - As with the embodiment described earlier herein, during installation, the
release sheet 134 is removed and discarded (FIG. 13 ), and the covering ortile 102 is tacked into place. When the position of the covering ortile 102 is properly positioned on thesurface 120, theother release liners top surface 108, as illustrated inFIG. 14 , leaving the center portion of the covering ortile 102 tacked in place. Each subsequent covering ortile 102 is installed (FIGS. 15B-18 ) and the adhered coverings andtiles 102 are used as a guide as well as using the indicia on the at least oneremovable label 186 as a guide. Because the adhesive 116 is applied in the adhesive bands, lines, strips orrows 116 a and does not entirely cover thebottom surface 110, the bond or connection between thebottom surface 110 and thesurface 120 can be broken by applying an upward force (as viewed inFIG. 15B ) to the covering ortile 102. As mentioned earlier, because of the difference in bond strength, the adhesive 116 is pulled from thesurface 120 and a majority of it remains with the covering ortile 102, rather than adhering to thesurface 120 which is a significant improvement over the prior art. - This feature also enables covering or
tiles 102 to be selectively replaced. As with the embodiment described earlier, this feature provides for a longer life to the overall surface covering because damaged or worn pieces may be replaced while leaving the remainder of the coverings ortiles 102 in tact. Because the adhesive 116 spans the entire width of thebottom surface 110, the covering ortile 102 is securely bonded to thesurface 120 and resists shifting or bunching when a load is applied, such as when a vehicle rides over it. - Referring now to
FIGS. 20-24 , another embodiment of the invention is shown. This embodiment is also directed to a surface covering or overlay in the form of tiles, particularly suited for covering a solid surface, such as a floor, garage floor, patio, an interior or exterior environment, an environment subject to exposure to elements or an environment subject to heavy traffic and high loads, such as airports, retail stores and the like. This embodiment is particularly suited for covering large expanses of exterior or interior solid surfaces or surfaces subject to the elements or harsh conditions. The embodiment can also be used for covering other types of surfaces including, but not limited to, basement floors, factory or retail floors, common areas, public areas, walkways or patios as mentioned earlier. - As with the other embodiments, the tiles in accordance with this embodiment are also suited for connection to surfaces formed of concrete. This embodiment may also be used on other exterior surfaces including concrete, synthetic composites, wood boards and plastic or plastic composite boards or any other suitable flat surface.
- A feature of this embodiment is that it utilizes the same system and method for providing an adhesive that is pressed directly into the surface of the fibers of the backing. In this embodiment, the
web 104 could be provided with or without a backing or coating, but it could have an adhesive, described earlier herein, applied directly to the fibers and pressed therein. As with the embodiment described earlier, this feature facilitates using the system and method with needle-punched products or webs. It should be understood that the adhesive described herein is selected to provide a desired amount of bond as described earlier herein. - Accordingly, those parts in
FIGS. 20-24 that bear the same part number as the parts identified relative to the prior embodiments identify the same or substantially the same part. - In the embodiment of
FIGS. 20-24 , another system andmethod 300 is shown for applying adhesive and release liners to theweb 104 in the manner described earlier herein and then presenting theweb 104 to a cutting station 302 (FIGS. 20 and 23 ) and cutting theweb 104 in the matter described herein. - As illustrated in
FIGS. 20-24 , thesystem 300 comprises an air table 304 comprising a topplanar member 304 a that defines a working area, working surface or surface 304 a 1, a generally opposed second or bottomplanar member 304 b (FIG. 23 ) and a plurality ofside walls 304 c (FIGS. 21A and 21C ). The table 304 comprises a plurality oflegs 308 secured to the bottomplanar member 304 b for supporting the table 304 above the ground. Themembers side walls 304 c are aluminum and welded together to provide and define an area orair chamber 314 as best shown inFIG. 23 . - The top
planar member 304 a comprises a plurality of apertures 306 (FIGS. 21A and 23 ) for permitting airflow and providing negative and positive pressure to theweb 104 in the manner described herein. Note that the chamber orarea 314 is in fluid communication with the plurality ofapertures 306. The table 304, pressure andfeed rollers web 104 prior to, during and after cutting. - As shown in
FIGS. 21A-23 , apositive pressure fan 316 is coupled to abottom portion 318 of thechamber 314 and in fluid communication with anaperture 320 to provide positive air pressure into thearea 314, through theapertures 306 and to thesurface 304 a 1. During positive pressure, air flows through theapertures 306 over thesurface 304 a 1 and provides an air cushion AC (seeFIGS. 21A-21H ) that provides a low friction surface. The positive airflow through theapertures 306 provides a low friction, air cushion (labeled AC inFIGS. 22 and 24 ) or air support for theweb 104 to move across asurface 304 a 1 of themember 304 a. In a manner described later herein, the air cushion AC supports theweb 104 over thesurface 304 a 1 to facilitate movement and transferring of theweb 104 in the manner described herein. - The
system 300 further comprises anegative pressure fan 322 that is coupled to avalve 324 which, in turn, is coupled to, and under the control of, theroller controller 156 as shown. During operation and as described later herein, when thevalve 324 is open, thefan 322 evacuates thechamber 314 through anaperture 330 and provides a negative pressure and vacuum to thesurface 304 a 1 via theapertures 306. When thevalve 324 is open, the negative pressure is greater than the positive pressure provided by thefan 316 and overcomes the positive pressure to provide a vacuum through theapertures 306. This vacuum facilitates holding theweb 104 against thesurface 304 a 1 and providing tension or resistance against movement of theweb 104, which feature is described later. - The
surface 304 a 1 further comprises a plurality oflaser apertures lasers web 104. - For ease of illustration, the
lasers top surface 108. Also, the lasers 162-168 in all embodiments are supported on a conventional metal frame or track (not shown for ease of illustration understanding) for transverse movement across the path of theweb 104. - As described later herein, when the
lasers valve 324 is caused to be opened to provide the negative pressure in thechamber 314 which causes thechamber 314 to be exhausted through the aperture 330 (FIG. 23 ) inmember 304 b to which thefan 322 andvalve 324 are in fluid communication. When thelasers web 104, any fumes are exhausted through theapertures port 330 by thefan 322. In this illustration, thefans fan 322 is coupled to thechamber 314 through thevalve 324, which is opened, for example, when thelasers web 104 at the cuttingstation 302 during cutting. In the illustration being described, thefan 316 provides airflow of about 250 cfm to provide the positive pressure, whilefan 322 provides an airflow of about 500 cfm to provide the negative pressure. The operation and airflow will be described later herein. - Referring to
FIGS. 20-23 , notice that thesystem 300 comprises alaser sensor 332 having atransmitter 334 and a target orreceiver 336. Thelaser sensor 332 is coupled to theroller controller 156 that energizeslaser drivers 170 to drive thelasers web 104 in the manner described herein. As best illustrated inFIGS. 21A and 23 ,transmitter 334 andreceiver 336 are operatively positioned to capture and sense anend 104 k of theweb 104. Theroller controller 156 receives the sensed information from thelaser sensor 332 and uses it to energize thefeed roller drivers 154 to accurately position theweb 104 at the cuttingstation 302 so that tiles T1 and T2 (FIG. 21H ) in the illustration may be accurately cut. This operation will be described in more detail later herein. - As best illustrated in
FIGS. 21A-21H , after tiles T1 and T2 are cut at cuttingstation 302, they are moved onto a movingconveyor 340 for transporting to a stacking or packaging area where they can be stored or packaged in containers for shipping. In the illustration being described, it should be understood that theconveyor 340 is coupled to a conveyor drive (not shown) that drives theconveyor 340 at a speed that is greater than the speed at which thefeed rollers web 104 to the cuttingstation 302. Consequently, when a portion of the tile, such as tile T1 inFIG. 21 F, is received on theconveyor 340 it is “grabbed” or “pulled” off thesurface 304 a 1 at a speed that is greater than the speed at which the tile T2 andweb 104 travels. This provides a separation distance SD (FIG. 21H ) between the cut tiles T1 and T2, which in turn facilitates processing the tiles T1 and T2 for packaging or shipping as may be desired. - A plurality of end-of-run
sensors 342 and 344 are associated with theends apertures FIG. 20 . The end-of-runsensors 342 and 344 sense when thelasers sensors 342 and 344 are coupled to theroller controller 156 which deenergizes thelaser drivers 170 andlasers lasers web 104 in the manner described herein. In the illustration, the end-of-runsensors 342 and 344 are provided inlaser controller driver 170 software which may be programmed by a user. In this regard, thelaser controller driver 170, mechanisms, support, including any frames, gantries, support structures or drivers necessary for controlling and driving thelasers lasers CO 2 150 watt lasers available from Coherent Inc. of Santa Clara, Calif. The system and method for cutting theweb 104 will now be described relative toFIGS. 20-21H . - With the prior embodiment and as illustrated in
FIG. 20 , theweb 104 is provided in a predetermined width for applying the adhesive andrelease liners FIGS. 1-19I . If necessary, one or more slitters 350 (FIG. 20 ) may be provided for slitting a supply of material into theweb 104 having a desired or predetermined width. The adhesive andrelease liners - A pair of
guides web 104 to the cuttingstation 302. As illustrated inFIGS. 21A , 21E-21F and 24, notice that at least one of the guides, guide 315 in the example, is adjustable and can be moved to different positions relative to the opposingguide 317 using thebolts 319 and complementary threadedholes 321 inmember 304 a. Note that theguides FIGS. 23 and 24 ) to facilitate permitting thelasers guides web 104 is slit and the adhesive andrelease liners web 104 is fed between theguides web 104 to the cuttingstation 302 for cutting in the manner that will now be described. - For ease of illustration,
FIGS. 21A-21H are views that do not show the various application steps upstream of therollers FIGS. 21A-21B , theroller controller 156 energizes thefeed roller driver 154 to rotatably drive thefeed rollers web 104 until theend 104 k is sensed by thesensor 332 using thetransmitter 334 andtarget 336. It should be appreciated that when theweb 104 is being advanced or moved over thesurface 304 a 1, thevalve 324 is closed andfan 316 provides positive air pressure to enable theweb 104 to easily float or move with low friction on the air cushion AC (FIGS. 22 and 23 ) over or across thesurface 304 a 1. - When the
sensor 332 senses theend 104 k, thesensor 332 generates a signal which is received by theroller controller 156 which internally marks the position and which causes thefeed roller driver 154 to cease advancing theweb 104 as shown. Theroller controller 156 actuatesvalve 324 to open which causes the negative pressure to vacuum and forceweb 104 againstsurface 304 a 1. Theroller controller 156 substantially simultaneously energizesfeed roller driver 154 to cause thefeed rollers web 104 is driven backwards (as viewed inFIG. 21C ) against the vacuum pressure and in the direction ofarrow 352 inFIG. 21C for a predetermined distance from the position, such as distance DW1, which is programmed into theroller controller 156. In the illustration being described, theroller controller 156 can be programmed so that the distance DW1 can be any desired or predetermined distance, dimension or size. In the illustration being described, theroller controller 156 is a programmable controller available from Kern Electronics & Lasers, Inc. of Wadena, Minn. - Thus, it should be understood that the
roller controller 156 comprises means for accurately energizing thefeed roller drivers 154 to cause therollers edge 104 k becomes situated at the predetermined distance fromlaser 164 so that when thelaser 164 moves transversely across theweb 104 and cuts the tile T1, the tile T1 is cut at the desired dimension width or distance DW1. In the illustration being described, square tiles are cut and the dimension is approximately 12 inches in the illustration, but as with the prior embodiments, other non-square shapes (e.g. polygonal, circular, elliptical, irregular, non-symmetrical and the like) sizes or dimensions (e.g., 18 inches, 24 inches, 36 inches, 48 inches and other sizes.) may be selected as well. - Returning to the illustration, once the
web 104 has been retracted so that the distance DW1 is achieved, theroller controller 156 ceases energizing thefeed roller drivers 154. It should be understood that theweb 104 is retracted while thevalve 324 is open and the negative pressure is applied thereto. The inventor has found that this negative pressure provides resistance or tension that facilitates registering and accurately positioning theweb 104 and cutting theweb 104 at the cuttingstation 302. - As illustrated in
FIG. 21C , the plurality oflasers web 104 is substantially the same, but it should be understood that these dimensions or distances could be different if desired. - After the
web 104 is moved to the position such that the dimension or distance between thesurface 304 a 1 and laser beam 164 a is substantially the distance DW1, theweb 104 is laser cut as mentioned earlier. As mentioned, thevalve 324 remains open which not only provides negative pressure and resistance to theweb 104, but also causes the exhaust fumes from the laser cut and/or debris to be evacuated by thefan 322. As mentioned earlier herein, it should be understood that the pressure provided by thefan 322 is greater than the pressure provided by thefan 316 so that a negative pressure is created atsurface 304 a 1. Advantageously and as shown inFIG. 21C and 21D , this negative pressure also facilitates securing theweb 104 against thesurface 304 a 1 without the use of any platen or other means for holding theweb 104 to thesurface 304 a 1, as well as functions to evacuate the fumes resulting from the laser cut to exhaust 325. - Continuing with the illustration, as the
web 104 is being held to thesurface 304 a 1, theroller controller 156 energizes thelaser drivers 170 to drive thelasers web 104 from the position shown inFIG. 21D to the phantom position shown inFIG. 21D , thereby resulting in the tiles T1 and T2 being cut. In the illustration being described, the end-of-run sensor 344 senses thelasers web 104 selected distance past the side edges, such as edge 104 l (FIG. 21D ). The sensed information is provided to theroller controller 156 which then actuates thevalve 324 to the closed position which ceases negative pressure fromfan 322 and enables positive pressure from fan 316 (FIGS. 21E and 21G ) to resume and to provide the air cushion AC to support theweb 104 above thesurface 304 a 1. Theroller controller 156 also energizes thefeed roller drivers 154 to advanceweb 104 which pushes the cut tiles T1 and T2 toward theconveyor 340 and in the direction of arrow 356 (FIG. 21F ). As theweb 104 is driven, the tile, such as tile T1, is received on theconveyor 340 as illustrated inFIG. 21G . At this time or preferably after the tiles T1 and T2 have been cut, thelabel 186 may be applied to the tiles T1 and T2. - As mentioned earlier herein, the
conveyor 340 is driven at a higher speed than the speed at which therollers web 104 so that when the tile T1 is picked up by theconveyor 340 it is pulled onto the conveyor'ssurface 340 a and the separation distance SD (FIG. 21H ) is created between the cut tiles T1 and T2. As illustrated inFIGS. 21F-21G , the second tile T2 is also received on theconveyor surface 340 a and pulled and separated form the end 104 l (FIG. 21H ) as shown. Note that theweb 104 is advanced until theend 104 k (FIG. 21H ) is sensed by thelaser sensor 332 at which time the process and system repeats the cutting procedure in the manner described earlier relative toFIGS. 21B-21H . - Advantageously, this system and method provide means for supporting the
web 104 above thesurface 304 a 1 and for facilitating moving theweb 104 over thesurface 304 a 1 and to the cuttingstation 302. The system and method also provide means for securing theweb 104 against thesurface 304 a 1 during cutting by thelasers lasers apertures method 300 provide means and apparatus for supporting theweb 104 with the air cushion AC and/or for facilitating low friction movement and travel of theweb 104 over thesurface 304 a 1, while substantially simultaneously providing resistance to movement of the web 104 a 1 and facilitating securing theweb 104 with negative pressure against thesurface 304 a 1 without the need for any platens or other holding devices which can cause misalignment and misregistration of theweb 104 during cutting. - Advantageously, the various embodiments enable, among other things, cutting of the
web 104 after the adhesive 116 is applied and therelease liners web 104 from thetop surface 108 if desired, and without any backing or support of the type used with prior art cutters like knifes and blades. Various advantageous unique features are achieved by the embodiments described herein, including but not limited to: - Utilizing multiple release tapes or
liners FIGS. 13 and 14 ); - Illustrating a nap direction on surface of the tile with label 186 (
FIGS. 15A-17 ); - Using a diffusing laser beam to create an angled cut or undercut bevel (
FIGS. 10-12 ), with most cases, laser cuts through from the top surface of the tile; and - Providing the air table 304 that provides ease of maneuvering the
web 104 and tile material utilizing positive and negative pressure with a mode of operation at this time to apply constant positive air flow and pressure during forward movement of theweb 104 and then applying negative pressure exceeding the positive air flow or pressure when necessary, such as when backing up theweb 104 and while cutting the tiles T1 and T2. - Various modifications can be made in my invention as described herein, and many different embodiments of the device and method can be made while remaining within the spirit and scope of the invention as defined in the claims without departing from such spirit and scope. It is intended that all matter contained in the accompanying specification shall be interpreted as illustrative only and not in a limiting sense.
Claims (60)
1. A system of manufacturing a covering for installation on a surface, said system comprising:
at least one web handler for driving a web of fibers to a cutting station;
an air table having a working surface and adapted to provide air pressure to facilitate movement and positioning the web at said cutting station; and
a cutter located at said cutting station for cutting the web of fibers into the covering having a predetermined shape.
2. The system as recited in claim 1 wherein said air table comprises an air chamber, said working surface comprising a plurality of apertures for permitting airflow between said air chamber and said working surface.
3. The system as recited in claim 1 wherein said system further comprises:
at least one fan for providing positive and negative pressure to said working surface of said air table in response to a position of said web.
4. The system as recited in claim 3 wherein said system further comprises:
a controller for controlling operation of said at least one fan in order to apply positive air flow, and apply negative pressure exceeding the positive air flow when desired.
5. The system as recited in claim 4 wherein said negative pressure is applied when either the web of fabric is backed up or the web of fabric is cut.
6. The system as recited in claim 3 wherein said at least one fan comprises:
a first fan in fluid communication with an air chamber in said air table for providing said positive pressure to said working surface of said air table;
a second fan in fluid communication with an air chamber in said air table for providing said negative pressure to said working surface of said air table;
wherein said negative pressure exceeds said positive pressure to urge a side of said web of fabric against said working surface.
7. The system as recited in claim 4 wherein said negative pressure is also sufficient to exhaust any fumes or debris created by said cutter.
8. The system as recited in claim 7 wherein said cutter comprises at least one laser cutter situated above said working surface.
9. The system as recited in claim 3 wherein said system comprises:
at least one sensor for sensing a position of said web of fabric;
a controller coupled to said sensor, said controller switching between said positive pressure and negative pressure in response thereto.
10. The system as recited in claim 9 wherein when said controller causes said negative pressure, said web handler drives said web in a direction opposite a feeding direction to cause said web to be positioned at said cutting station.
11. The system as recited in claim 4 wherein when said web is positioned at said cutting station, said controller causes said cutter to cut said web while said negative pressure is applied, said working surface being adapted so that said negative pressure exhausts fumes debris arising from said cutting and also retains the web of fabric against said working surface at the cutting station.
12. The system as recited in claim 9 wherein said controller is programmed to cause said at least one web handler to drive said web of fabric past said cutting station and subsequently retract said web of fabric a predetermined distance and against said negative pressure.
13. The system as recited in claim 12 wherein said controller energizes said at least one fan to generate said negative pressure in response to said at least one sensor sensing an end of said web of fabric.
14. The system as recited in claim 1 wherein said system comprises:
an application station upstream of said air table for applying an adhesive directly to a fibrous layer of said web of fibers.
15. The system as recited in claim 14 wherein said system comprises:
a pressing station for pressing the adhesive into said web of fibers.
16. The system as recited in claim 1 wherein said cutting station comprises:
at least one laser cutter that cuts said web of fibers.
17. The system as recited in claim 1 wherein said cutting station comprises:
at least one laser cutter and at least one laser driver that drives said at least one laser cutter to laser cut said web in a direction that is transverse the direction of movement of said web through said cutting station.
18. The system as recited in claim 17 wherein said at least one laser cutter is positioned to cut said web of fabric through at least one of a fabric side or a top surface thereof.
19. The system as recited in claim 18 wherein said at least one laser cutter cuts an angled or beveled undercut of said web of fabric that diverges away from said top surface.
20. The system as recited in claim 16 wherein said at least one laser cutter cuts said web of fibers from a non-adhesive side of said web of fibers and after an adhesive is applied to an adhesive side.
21. The system as recited in claim 16 wherein said at least one laser cutter comprises a plurality of laser cutters that are driven in a path that is substantially perpendicular or transverse to adjacent paths.
22. The system as recited in claim 21 wherein said predetermined shape is a square.
23. The system as recited in claim 1 wherein said system further comprises:
a removable label applying station for applying at least one removable indicia to a top surface of said covering, said removable indicia providing an indication of a nap of said fibers.
24. The system as recited in claim 15 wherein said pressing station causes said adhesive to be flattened on a bottom surface.
25. The system as recited in claim 15 wherein said application station comprises:
an adhesive applier for applying said adhesive on said web of fibers in beads or strips;
said pressing station comprising at least one roller for pressing each of said beads or strips so that a first portion of each of said beads or strips becomes pressed into said web of fibers and a second portion of said beads or strips becomes flattened out on a bottom surface of said web of fibers to form bands, lines, strips or rows.
26. The system as recited in claim 25 wherein said adhesive is a removable adhesive that is pressed into said bottom surface and extends beyond said bottom surface a distance of at least ten thousandths of an inch.
27. The system as recited in claim 14 wherein said system further comprises:
a release liner application station located downstream of said application station for removably securing a plurality of release sheets to said adhesive.
28. The system as recited in claim 1 wherein said covering defines a carpet tile.
29. A method for cutting a covering or tile comprising the steps of:
positioning a web of fabric at a cutting station using an air table having a working surface and a plurality of apertures for providing a cushion of air; and
cutting said web of fabric with a cutter to provide the covering or tile having a predetermined shape.
30. The method as recited in claim 29 wherein said positioning step further comprises the steps of:
using positive pressure to provide said cushion of air when said web is being moved to said cutting station;
using negative pressure on said web of fabric during a predetermined event.
31. The method as recited in claim 30 wherein said predetermined event is at least one of said web of fabric being moved in a direction opposite a feeding direction of said web of fabric or cutting during said cutting step.
32. The method as recited in claim 29 wherein said method further comprises the step of:
using an air table comprising an air chamber in fluid communication with said working surface over which said web of fabric may move on said cushion of air, said working surface comprising a plurality of apertures for permitting airflow between said air chamber and said working surface.
33. The method as recited in claim 32 wherein said method further comprises the step of:
using at least one fan coupled to said air chamber for providing positive and negative pressure to said working surface of said air table in response to a position of said web of fabric.
34. The method as recited in claim 33 wherein said method further comprises the step of:
controlling operation of said at least one fan in order to apply positive pressure, and apply negative pressure exceeding the positive pressure during a predetermined event.
35. The method as recited in claim 34 wherein said predetermined event is at least one of said web of fabric is being positioned for cutting at said cutting station or cutting of said web of fabric occurs.
36. The method as recited in claim 33 wherein said method comprises the steps of:
using a first fan in fluid communication with said air chamber for providing said positive pressure to said working surface of said air table;
using a second fan in fluid communication with said air chamber for providing said negative pressure to said working surface of said air table;
wherein said negative pressure exceeds said positive pressure to hold said web of fabric during said cutting step.
37. The method as recited in claim 36 wherein said air table comprises a plurality of apertures, at least one of which being associated with said cutter, said negative pressure being sufficient to exhaust any fumes or debris created by said cutter.
38. The method as recited in claim 29 wherein said cutter comprises at least one laser.
39. The method as recited in claim 30 wherein said method comprises:
sensing a position of said web of fabric;
switching between said positive pressure and negative pressure in response thereto.
40. The method as recited in claim 29 wherein said method comprises the step of slitting the web of fabric to a predetermined width prior to said positioning and cutting steps.
41. The method as recited in claim 34 wherein said method comprises the step of:
controlling air pressure at said working surface to facilitate movement of said web of fabric thereover or to urge said web of fabric thereagainst.
42. The method as recited in claim 41 wherein said controlling step comprises the step of:
controlling the operation of at least one fan coupled to said air chamber to perform said controlling step.
43. The method as recited in claim 34 wherein said method comprises the step of:
causing said negative pressure when said web of fabric is driven in a direction opposite a feeding direction.
44. The method as recited in claim 34 wherein said cutter comprises at least one laser, said method comprising the step of:
causing said at least one laser to cut said web while said negative pressure is applied to said web, said working surface being adapted so that said negative pressure exhausts at least one of fumes and debris arising from said cutting and also urges the web of fabric against the working surface at the cutting station during cutting.
45. The method as recited in claim 29 wherein said method further comprises the steps of:
moving said web of fabric on said cushion of air past said cutting station;
causing negative pressure at said working surface to force said web of fabric against said working surface;
retracting said web of fabric against said negative pressure to said cutting station.
46. The method as recited in claim 45 wherein said cutting step further comprises the step of:
laser cutting said web of fabric during said negative pressure.
47. The method as recited in claim 45 wherein said cutter is a laser cutter and said working surface is adapted to receive fumes and/or debris caused by laser cutting, said step of causing negative pressure further comprising the step of:
causing negative pressure at said working surface sufficient to exhaust said fumes and/or debris.
48. The method as recited in claim 45 wherein said method further comprises the steps of:
sensing an end of said web of fabric;
causing negative pressure in response to said sensing of said end of said web of fabric.
49. The method as recited in claim 29 wherein said method comprises the step of:
applying adhesive directly to said web of fabric upstream of said air table.
50. The method as recited in claim 29 wherein said method comprises the step of:
pressing an adhesive into said web of fabric.
51. The method as recited in claim 29 wherein said cutting station comprises:
using a plurality of laser cutters to perform said cutting step.
52. The method as recited in claim 29 wherein said cutting station comprises:
driving at least one laser cutter in a direction that is transverse the direction of movement of said web to laser cut said web.
53. The method as recited in claim 52 wherein said method further comprise the step of:
cutting said web of fabric through at least one of a fabric side or a top surface thereof.
54. The method as recited in claim 52 wherein said at least one laser cutter cuts an angled beveled undercut or cut in said web of fabric that diverges away from a top surface of said web of fabric.
55. The method as recited in claim 52 wherein said at least one laser cutter cuts said web of fabric from a non-adhesive side of said web of fibers and after an adhesive is applied to an adhesive side.
56. The method as recited in claim 52 wherein said at least one laser cutter cuts said web of fibers to define at least one edge, said at least one edge lying in a plane that is not perpendicular with respect to either a non-adhesive side or an adhesive side.
57. The method as recited in claim 52 wherein said at least one laser cutter comprises a plurality of laser cutters that are driven in a path that is substantially perpendicular or transverse to a direction of said web of fabric to perform said cut.
58. The method as recited in claim 29 wherein said predetermined shape is a square.
59. The method as recited in claim 29 wherein said method further comprises the step of:
applying at least one removable indicia to a top surface of said covering, said removable indicia providing an indication of a nap of said web of fabric.
60. The method as recited in claim 29 wherein said covering defines a carpet tile.
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US12/181,498 US20090031870A1 (en) | 2007-08-02 | 2008-07-29 | System and method for cutting a web to provide a covering |
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US12/181,498 Abandoned US20090031870A1 (en) | 2007-08-02 | 2008-07-29 | System and method for cutting a web to provide a covering |
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