Single pass carpet-production method and carpets prepared using same
AssigneeAladdin Manufacturing Corporation
InventorMichael E. Bell
Life of this patent
Estimating the term…
Abstract
A low-weight carpet or carpet tile and process for making the same, wherein the carpet or carpet tile comprises a facecloth having a plurality of face yarns tufted through a primary backing, a low-viscosity polyolefin coating layer applied to the primary backing, a reinforcing scrim layer, and an extruded polyolefin sheet. The top surface and bottom surface of the carpet tile are defined by the facecloth and either the extruded polyolefin sheet or the reinforcing scrim layer, respectively. The entire multi-layer web is then passed through a nip to compress the layers together, and the entire web is chilled before optionally being cut into tiles.
Claims20
A method of manufacturing a carpet or carpet tile, the method comprising:
- providing a facecloth, wherein the facecloth comprises a primary backing having a plurality of face yarns extending through the primary backing;
- forming a multi-layer construction comprising the facecloth and a backing construction secured on a bottom side of the facecloth by:
- applying a polyolefinic coating onto the bottom side of the facecloth;
- pressing a first side of a reinforcing scrim layer onto the polyolefinic coating applied to the bottom side of the facecloth;
- and
- extruding a polyolefin-based resin onto a second side of the reinforcing scrim layer, thereby forming an extruded polyolefin sheet having a top surface which is bonded to the reinforcing scrim layer;
- and
- wherein the polyolefinic coating has a viscosity less than 2000 mPa·s at 400° F., and the reinforcing scrim layer comprises a composite material of a first layer of a polymer-based fiber material and a second layer of a glass fiber material.
A method of manufacturing a carpet or carpet tile, the method comprising:
- providing a facecloth, wherein the facecloth comprises a primary backing having a plurality of face yarns extending through the primary backing;
- and
- forming a multi-layer construction comprising the facecloth and a backing construction secured on a bottom side of the facecloth by:
- applying a polyolefinic coating onto the bottom side of the facecloth;
- extruding a polyolefin-based resin onto the bottom side of the facecloth, thereby forming an extruded polyolefin sheet having a top surface which is bonded to the facecloth;
- and
- pressing a first side of a reinforcing scrim layer at least partially into a bottom surface of the extruded polyolefin sheet;
- and
- wherein the polyolefinic coating has a viscosity less than 2000 mPa·s at 400° F., and the reinforcing scrim layer comprises a composite material of a first layer of polymer-based fiber material and a second layer of a glass fiber material.
A carpet tile comprising:
- a facecloth comprising a primary backing and a plurality of face yarns extending through the primary backing, wherein a top side of the facecloth defines an upper surface of the carpet tile;
- a polyolefinic coating absorbed into the face yarns and present on a bottom side of the facecloth;
- an extruded polyolefin sheet formed by extruding a polyolefin-based resin;
- and
- a reinforcing scrim layer;
- wherein the extruded polyolefin sheet and the reinforcing scrim layer are bonded together;
- wherein the extruded polyolefin sheet is bound to the polyolefinic coating on the bottom side of the facecloth, and wherein the reinforcing scrim layer defines at least a portion of a bottom surface of the carpet tile;
- and
- wherein the polyolefinic coating has a viscosity less than 2000 mPa·s at 400° F., and the reinforcing scrim layer comprises a composite material of a first layer of polymer-based fiber material and a second layer of a glass fiber material.
Dependencies are inferred from the claim text.