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US 2004/0062902 A1Published application
Dual denier tufted carpet construction
OwnerKeith S. Henry, Lyle E. Johnsoninventors
Life of this patent
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Abstract
A vehicle carpet module comprising a segment of tufted carpet including contiguous portions formed with at least two different sizes of yarn. A mass backing layer is attached to the rear surface of the carpet segment. The carpet module is shaped and sized to cover the floor of a specific motor vehicle.
Claims22
A vehicle carpet module comprising:
- a first portion of carpeting including a yarn having a first size;
- and
- a second portion of carpeting adjacent to said first portion of carpeting, said second portion of carpeting including a yarn having a second size, said second yarn size being less than said first yarn size, whereby the weight of the vehicle carpet is less that a similar vehicle carpet including only said yarn having said first size.
A vehicle carpet module comprising:
- a segment of tufted carpet including at least two contiguous portions, each of the tufted carpet portions including a different size of yarn;
- and
- a mass backing layer attached to the rear surface of said carpet segment, said carpet and mass backing layer being shaped and sized to cover the floor of a specific motor vehicle.
A process for forming a vehicle carpet module comprising the steps of:
- (a) forming a tufted carpet including at least two contiguous portions, each of the tufted carpet portions including a different size of yarn;
- (b) coating the under surface of the carpet with a mass layer material;
- (c) cutting the coated carpet into segment;
- (d) heating the carpet segments sufficiently to soften the mass layer material;
- and
- (e) pressing the heated carpet segments within a die set to mold the segments into a shape corresponding to the floor of the passenger compartment of a specific motor vehicle.
3 more elements
Dependencies are inferred from the claim text.