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US 2021/0156084 A1Published application
Lightweight Carpet Tile and Method
OwnerPaul Walkerinventor
Life of this patent
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Abstract
A novel carpet tile is provided with a roller applied polyurethane adhesive layer at a rate of less than 45 ounces per square yard, resulting in a lightweight backing with exceptional dimensional stability.
Claims20
A rectangular carpet tile product consisting essentially of:
- a greige with a primary backing material having tufted face yarns extending from a face side and an opposite backstitch side;
- a single layer of polyurethane compound applied by roller coating at a rate of less than 30 ounces per square yard to the backstitch side of the greige;
- a secondary backing fabric having a front side adhered to the single layer of polyurethane compound;
- a pressure sensitive adhesive on an opposite back side of the secondary backing fabric;
- and
- a release sheet covering the pressure sensitive adhesive;
- wherein the carpet tile is dimensionally stable in ASTM D7570 testing and has edges with a length of about 18 to 24 inches.
4 more elements
The carpet tile of claim 6 wherein the polyurethane compound is applied at a rate of less than 25 ounces per square yard.
A rectangular carpet tile product comprising a greige with a primary backing material having tufted face yarns extending from a face side and an opposite backstitch side;
- a single layer of polyurethane compound applied by roller coating to the backstitch side of the greige and a front side of a secondary backing fabric adhered to the single layer of polyurethane compound;
- the polyurethane compound comprising polyol, isocyanate, and filler, with the ratio of filler to polyol is greater than 2.5 to 1, and the polyurethane compound applied to the backstitch side at a rate of between 14 and 30 ounces per square yard;
- wherein the carpet tile is dimensionally stable in ASTM D7570 testing without additional stabilizing or reinforcing layers.
Dependencies are inferred from the claim text.