Textile product and method
OwnerKenneth B. Higgins, William Tippett +1inventors
InventorsKenneth B. Higgins, William Tippett, Scott C. Miller
Life of this patent
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Abstract
A layered cushioned composite which in one embodiment incorporates a glass layer of stabilizing material disposed within a layer of adhesive material below a primary carpet surface such that the adhesive material extends in covering relation away from each side of the stabilizing material and performs the dual functions of securing the stabilizing material at a defined position below the underside of the primary carpet and forming an attachment surface for an adjacent layer of underlying recycled foam or rebond foam cushioning material.
Claims142
A surface covering such as a wall covering, floor covering, carpeting, or carpet tile, comprising:
- a primary carpet, and a rebond foam cushion fixed at a position below said primary carpet.
A surface covering such as a wall covering, floor covering, carpeting, or carpet tile, comprising:
- a primary carpet, a polyurethane rebond foam cushion disposed at a position below said primary carpet, a mass of adhesive material disposed in bonding relation between said primary carpet and said rebond foam cushion and a layer of reinforcing material disposed between said primary carpet and rebond foam cushion such that at least a portion of said mass of adhesive material extends away from at least one side of said layer of reinforcing material.
A method of forming a surface covering such as a carpet tile or carpet composite comprising the steps of:
- bonding at least one layer of rebond foam to the underside of a primary carpet fabric.
A method of forming a cushion backed carpet composite comprising the steps of:
- bonding a layer of rebond foam to the base of a primary carpet fabric with a layer of reinforcement material therebetween.
A dimensionally stable cushioned carpet tile suitable for disposition as discrete modular units across a flooring surface, the carpet tile comprising:
- a primary carpet fabric having a pile side and a primary base with a plurality of pile forming yarns projecting outwardly from the pile side;
- a rebond foam cushion layer disposed at a position below the primary carpet fabric;
- and
- a bridging composite extending in bonding relation substantially between the primary base and an upper side of the rebond foam cushion layer wherein the bridging composite consists essentially of a layer of stabilizing material having a first side and a second side, a first layer of at least one resilient adhesive extending away from the first side of the stabilizing material into contacting relation with the primary base and a second layer of at least one resilient adhesive extending away from the second side of the layer of stabilizing material into contacting relation with the upper side of the rebond foam cushion layer such that the layer of stabilizing material is bonded between the first and second layers of resilient adhesive at a position between the primary base and the rebond foam cushion layer.
A process for producing a carpet composite comprising the steps of:
- modifying a rebond foam pad of approximately 5-25 pounds/cubic foot density to have a respective non-woven material bonded to each of the upper and lower surfaces thereof and with the composite rebond pad having a thickness of approximately 0.25 inch or less, slitting the composite rebond pad in half, producing two foam backings, each approximately 0.125 inch thick or less with a non-woven material attached to one surface, and bonding at least one of the foam backings using an adhesive to the back of at least one of a tufted carpet and a bonded carpet.
A carpet tile comprising a carpet layer and a backing attached thereto and having at least one layer comprised of compressible particles bonded together.
A cushion back carpet tile comprising a carpet layer and a cushion back attached thereto and having at least one layer comprised of preformed foamed polyurethane particles bonded together.
A foam backed carpet tile with slit or peeled foam.
A foam backed carpet tile with open celled foam comprised of foamed polyurethane particles bonded together.
A foam backed carpet tile with a backing of bonded chips of resilient material attached to a textile face and a backing density of <14 lbs/ft3.
A foam backed carpet tile with a flame laminated foam backing.
A foam backed carpet tile with a backing of bonded chips of resilient material attached to a textile face and an initial Gmax of less than 125.
A cushion backed carpet tile with a carpet layer and a skeletal structured foam cushion.
A cushion backed carpet tile including a carpet layer and a backing layer with a total backing layer weight of less than 50 oz/yd2.
A carpet tile comprising a carpet layer and a backing attached thereto and having at least one layer comprised of foamed open cell particles bonded together.
A carpet tile with a cushion weight of less than 25 lbs/yd2 and an initial Gmax of less than 125.
A carpet tile comprising a carpet layer, a stabilizing layer, and a backing wherein at least one of said stabilizing layer and backing have at least one layer comprised of preformed compressible particles bonded together.
A cushion back carpet tile comprising a carpet layer, a stabilizing layer, and a cushion back having at least one layer comprised of preformed compressible particles bonded together.
A carpet tile having a recycled foam content of at least 50%.
A carpet tile having a recycled foam content of at least 85%.
A method of recycling post industrial or post consumer waste foam, comprising the steps of:
- reducing the foam to compressible particles having an average diameter of less than 25 mm,
- mixing the particles with a prepolymer to coat the particles with prepolymer,
- compressing the coated particles to a compression ratio of at least 2:1,
- curing the polymer and fixing the particles in the compressed state to form a rebond foam,
- and then using at least a portion of the rebond foam to form a backing or cushion of a carpet tile.
A method of producing a carpet tile having a carpet layer and a backing layer including at least one layer of rebond foam, comprising the steps of:
- forming the backing layer, then
- joining the backing layer to the carpet layer.
Dependencies are inferred from the claim text.