Method of making inlaid floor coverings
AssigneeCollins & Aikman Floorcoverings, Inc.
InventorsLee Hilton Schilling, Lorence M. Moot
Life of this patent
Estimating the term…
Abstract
A method of making a floor covering having decorative inlays therein is disclosed. The method comprises the steps of cutting and removing portions of the floor covering, providing inlays from another floor covering material having substantially the same shapes and sizes as the removed portions, and joining the inlays and floor covering to create a seamless structure. The seamless structure results from the application of a volatile solvent which causes the thermoplastic properties of the materials within the inlays and floor covering to fuse.
Claims26
A method of making a textile substrate characterized by having a decorative inlay therein, the textile substrate having an outer face, a primary backing to which the outer face is secured, and a secondary backing secured to the primary backing using a first thermoplastic resin coating composition, said method comprising the steps of:
- (a) removing a first portion from the textile substrate thereby creating an opening wherein vertical side faces are exposed in the first thermoplastic resin;
- (b) providing an inlay substantially identical in shape and size as the first portion and having an outer face, a primary backing to which the outer face is secured, and a secondary backing secured to the primary backing using a second thermoplastic resin coating composition, the second thermoplastic resin having vertical side faces;
- (c) inserting the inlay into the opening created in the textile substrate such that the inlay and the opening substantially coincide;
- and
- (d) fusing the vertical side faces of the first thermoplastic resin with the vertical side faces of the second thermoplastic resin such that the inlay and the textile substrate are fused together, without a reinforcing material on the underside surfaces of the inlay and the textile substrate, to create a substantially seamless textile substrate having a decorative inlay therein.
A method of making a tufted carpet characterized by having a decorative inlay therein, the tufted carpet having a primary backing and textile fibers extending from the primary backing, and a secondary backing secured to the primary backing using a first thermoplastic resin coating composition, said method comprising the steps of:
- (a) removing a first portion from the carpet, thereby creating an opening wherein vertical side faces are exposed in the first thermoplastic resin;
- (b) providing an inlay substantially identical in shape and size as the first portion and having a tufted outer face, a primary backing to which the outer face is secured, and a secondary backing secured to the primary backing using a second thermoplastic resin coating composition, the second thermoplastic resin having vertical side faces;
- (c) inserting the inlay into the opening created in the tufted carpet such that the inlay and the opening substantially coincide;
- (d) fusing the vertical side faces of the first thermoplastic resin with the vertical side faces of the second thermoplastic resin such that the inlay and the carpet are fused together, without a reinforcing material on the underside surfaces of the inlay and the carpet, to create a substantially seamless tufted carpet having a decorative inlay therein.
Dependencies are inferred from the claim text.