Carpet tile constructions and methods
OwnerJ. Todd Keith, Kenneth B. Higginsinventors
Life of this patent
Estimating the term…
Abstract
An improved flooring, floor covering, carpet, carpet tile, and method is provided. A hardback like carpet includes a primary carpet having a base and a plurality of pile-forming yarns projecting outwardly from one side. A layer of reinforcement material is bonded to the base on the side opposite the pile forming yarns. The reinforcement layer is adjacent to and may be embedded in, a layer of a polymer such as a polyurethane or hot melt. A non-woven backing is attached to the reinforcement layer by the polymer. An apparatus and process for forming the low weight cushioned carpet or carpet tile of the present invention are also provided.
Claims26
A surface covering, wall covering, flooring, carpet, roll product, or carpet tile as shown or described herein, comprising a carpet layer, an adhesive layer, and a non-woven backing.
A carpet tile, comprising a primary carpet, a thin polyurethane layer, and a non-woven cushion backing.
A carpet tile, comprising a layered structure of a primary carpet precursor, latex pre-coat adhesive, hot melt adhesive, fiberglass, polyurethane adhesive and felt.
A modular carpet tile comprising a layered structure of a primary carpet, bitumen hot melt layer, fiberglass, polyurethane adhesive, and felt.
A method of forming a modular carpet tile comprising the steps of:
- adhesively bonding a layer of glass reinforcement material to the base of a primary carpet fabric to form a laminate composite,
- placing a layer of mechanically frothed, wet polyurethane forming composition into direct contact relation with a layer of non-woven backing material to form a polyurethane layer of less than about 0.09 inches thick, and
- joining the polyurethane layer to the glass reinforcement material to form a modular carpet composite, and cutting carpet tiles from the carpet composite.
A method of marketing carpet to carpet customers, comprising the steps of offering to the customer at least one of each of standard cushion back carpet tile, low weight cushion back carpet tile and hardback carpet tile to satisfy all of their carpet needs and thereby replace broadloom carpet.
A method of producing hardback like carpet tiles using a cushion back carpet tile range, comprising the steps of:
- reducing the density of the polyurethane,
- and reducing the add-on of polyurethane.
A method of selectively producing one of three different carpet tile products using a polyurethane range, comprising the steps of:
- changing the carpet, adjusting the density of polyurethene, and adjusting the add-on of polyurethane.
Dependencies are inferred from the claim text.