Fiberglass fabric flooring system
AssigneeChilewich L.L.C.
InventorJoseph Sultan
Life of this patent
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Abstract
A hybrid of vinyl flooring and soft cushioned carpet is provided. The hybrid flooring, which is suitable for production into tiles, utilizes woven PVC fabric that is bonded to a flexible backing. The fabric comprises woven solid color and/or multi-color yarns in order to produce different visual styles. These yarns comprise a ceramic fiber core, preferably fiberglass, onto which PVC is extruded in order to form a PVC jacket. The core provides the yarn with sufficient tensile strength so it can be woven while the PVC provides durability, resistance to wear and color. After the fabric is woven, it is sent through a tentering or curing oven which fuses the warp and fill yarns of the fabric, thereby stabilizing the fabric, preserving its integrity and preventing it from unraveling.
Claims26
A method for producing a flooring system comprising:
- forming a plurality of ceramic yarns with kinks therealong in order to define a plurality of textured ceramic yarns;
- drawing said plurality of ceramic yarns through an extrusion element for coating each yarn with a polyvinyl chloride (PVC) jacket;
- weaving said PVC coated ceramic yarns into a fabric;
- bonding the fabric to a backing that is suitable for supporting said fabric in order to define a flooring;
- and
- cutting the flooring into a plurality of floor tiles.
A method for producing a flooring system comprising:
- forming a plurality of ceramic yarns with a diameter for each yarn of between about 5 and 15;
- drawing said plurality of ceramic yarns through an extrusion element for coating each yarn with a polyvinyl choloride (PVC) jacket;
- weaving said PVC coated ceramic yarns into a fabric;
- bonding the fabric to a backing that is suitable for supporting said fabric in order to define a flooring;
- and
- cutting the flooring into a plurality of floor tiles.
A method for producing a flooring system comprising:
- drawing said plurality of ceramic yarns through an extrusion element for coating each yarn with and bonding said ceramic yarn to said PVC jacket a polyvinyl chloride (PVC) jacket;
- weaving said PVC coated ceramic yarns into a fabric;
- bonding the fabric to a backing that is suitable for supporting said fabric in order to define a flooring;
- and
- cutting the flooring into a plurality of floor tiles.
A method for producing a flooring system comprising:
- forming a plurality of yarns, each defined by a ceramic core and a polyvinyl (PVC) jacket;
- said forming step including the step of bonding said core to said PVC jacket;
- weaving said plurality of yarns into a fabric;
- and
- disposing a backing in supporting position relative to said fabric in order to define a flooring.
A method for producing a flooring system comprising:
- drawing a plurality of ceramic yarns through an extrusion element for coating each yarn with a polyvinyl chloride (PVC) jacket having a thickness of between about 3 and 10 mills;
- weaving said PVC coated ceramic yarns into a fabric;
- bonding the fabric to a backing that is suitable for supporting said fabric in order to define a flooring;
- and
- cutting the flooring into a plurality of floor tiles.
Dependencies are inferred from the claim text.