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US 2014/0220304 A1Published application
Embossed carpet backing
AssigneeShaw Industries Group, Inc.
InventorGregory D. Fowler
Life of this patent
Estimating the term…
Abstract
Disclosed is a floor covering having an embossed polyurethane foam backing layer and methods of making and using same. A bottom surface of the backing layer can be thermo-embossed with a predetermined pattern, and the bottom surface of the backing layer can define at least one fluid pathway in communication with a side edge of the floor covering. The floor covering can also have a layer of skid-resistant material connected to the bottom surface of the backing layer.
Claims24
A floor covering having a plurality of side edges, comprising:
- a greige good having a face surface and a back surface;
- and
- an embossed backing layer having a top surface and an opposed bottom surface, wherein the top surface of the backing layer is connected to the back surface of the greige good, wherein the bottom surface of the backing layer is thermo-embossed with a pre-determined pattern, the predetermined pattern comprising a plurality of discrete spaced male projections extending away from a plane positioned within the partially cured polyurethane composition and oriented substantially parallel to the back surface of the greige good, wherein each male projection has a top surface, wherein adjacent male projections of the plurality of discrete spaced male projections cooperate to define a plurality of fluid pathways, wherein each fluid pathway is in communication with at least one side edge of the floor covering and configured to disperse fluid to the at least one side edge of the floor covering;
- and wherein each top surface of the plurality of discrete spaced male projections has a layer of skid-resistant material cured thereto,
- wherein the embossed backing layer is made by metering a foamable polyurethane composition to the back surface of the greige good to form a substantially uniform layer of the foamable polyurethane composition having a predetermined thickness, partially curing the foamable polyurethane composition, wherein the step of partially curing the foamable polyurethane composition comprises substantially curing at least about 60% of the foamable polyurethane composition, embossing the partially cured polyurethane composition to define the predetermined pattern, curing the embossed polyurethane composition, applying the layer of skid-resistant material to only the top surface of the plurality of discrete spaced male projections of the cured embossed polyurethane composition;
- and curing the layer of skid-resistant material,
- wherein the steps of partially curing the foamable polyurethane composition, curing the embossed polyurethane composition, and curing the layer of skid-resistant material are each separately performed in a belted oven.
4 more elements
A floor covering having a plurality of side edges, comprising:
- a greige good having a face surface and a back surface;
- and
- an embossed backing layer having a top surface and an opposed bottom surface, wherein the top surface of the backing layer is connected to the back surface of the greige good, wherein the bottom surface of the backing layer is thermo-embossed with a pre-determined pattern, the predetermined pattern comprising a plurality of discrete spaced male projections extending away from a plane positioned within the partially cured polyurethane composition and oriented substantially parallel to the back surface of the greige good, wherein each male projection has a top surface, wherein adjacent male projections of the plurality of discrete spaced male projections cooperate to define a plurality of fluid pathways, wherein each fluid pathway is in communication with at least one side edge of the floor covering and configured to disperse fluid to the at least one side edge of the floor covering;
- and wherein each top surface of the plurality of discrete spaced male projections has a layer of skid-resistant material cured thereto,
- wherein the embossed backing layer is made by metering a foamable polyurethane composition to the back surface of the greige good to form a substantially uniform layer of the foamable polyurethane composition having a predetermined thickness, partially curing the foamable polyurethane composition, wherein the step of partially curing the foamable polyurethane composition comprises substantially curing at least about 60% of the foamable polyurethane composition, embossing the partially cured polyurethane composition to define the predetermined pattern, curing the embossed polyurethane composition, applying the layer of skid-resistant material to only the top surface of the plurality of discrete spaced male projections of the cured embossed polyurethane composition;
- and curing the layer of skid-resistant material,
- wherein the step of partially curing the foamable polyurethane composition is performed in a first pass through an oven, wherein the step of curing the embossed polyurethane composition is performed in a second pass through the oven, and wherein the step of curing the layer of skid-resistant material is performed in a third pass through the oven.
4 more elements
Dependencies are inferred from the claim text.