# US 9,775,457 B2 · Floor covering with universal backing and methods of making and recycling

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- Number: US 9,775,457 B2
- Document ID: US9775457B2
- Status: Granted
- Kind: B2
- Application number: 15/372,465
- Filed: 2016-12-08
- Published: 2017-03-30
- Granted: 2017-10-03
- Earliest claimed: 2012-12-10
- Assignees: Higgins Research & Development, LLC
- Applicants: Higgins Research & Development, LLC
- Inventors: Kenneth B. Higgins
- Web page: https://patentgrep.com/patent/US9775457B2

## CPC

- A47G 27/02: Carpets; Stair runners; Bedside rugs; Foot mats (mat-like foot scrapers A47L23/22 {; doormats A47L23/26})
- B05C 3/18: only one side of the work coming into contact with the liquid or other fluent material (B05C3/02 takes precedence)
- B05C 11/023: {Apparatus for spreading or distributing liquids or other fluent materials already applied to a surface (B05C11/021, B05C11/04 take precedence)}
- B05C 11/025: {with an essentially cylindrical body, e.g. roll or rod}
- B05D 1/40: Distributing applied liquids or other fluent materials by members moving relatively to surface
- B32B 5/022: {Non-woven fabric}
- B32B 5/024: {Woven fabric}
- B32B 5/26: another layer {next to it} also being fibrous or filamentary {(relative arrangement of fibres or filaments of different layers B32B5/12)}
- B32B 7/12: using interposed adhesives or interposed materials with bonding properties
- B32B 27/12: next to a fibrous or filamentary layer
- B32B 27/308: {comprising acrylic (co)polymers}
- B32B 37/10: characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
- D05C 17/02: Tufted products
- D05C 17/023: {characterised by the base fabric}
- D06N 7/0071: {characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing}
- D06N 7/0073: {the back coating or pre-coat being applied as an aqueous dispersion or latex}
- A47G 27/0293: {Mat modules for interlocking engagement}
- B32B 37/1018: {using only vacuum}
- B32B 37/1284: {Application of adhesive}
- B32B 38/1858: {using vacuum}
- B32B 2037/148: {whereby layers material is selected in order to facilitate recycling of the laminate}
- B32B 2037/243: {Coating}
- B32B 2038/0072: {Orienting fibers}
- B32B 2250/03: 3 layers
- B32B 2262/0253: Polyolefin fibres
- B32B 2262/0276: Polyester fibres
- B32B 2305/188: Woven fabrics
- B32B 2307/50: having particular mechanical properties
- B32B 2307/58: Cuttability
- B32B 2307/734: Dimensional stability
- B32B 2307/744: Non-slip, anti-slip
- B32B 2471/00: Floor coverings (B32B2419/04 takes precedence)
- B32B 2471/02: Carpets
- D06N 7/0081: {with at least one extra fibrous layer at the backing, e.g. stabilizing fibrous layer, fibrous secondary backing}
- D06N 2201/0254: Polyolefin fibres
- D06N 2203/061: Polyesters
- D06N 2205/14: Fibrous additives or fillers
- D06N 2209/1628: Dimensional stability
- D06N 2211/066: Floor coverings
- D06N 2213/065: Two back coatings one next to the other
- D10B 2503/041: Carpet backings
- Y10T 156/10: Methods of surface bonding and/or assembly therefor
- Y10T 428/23979: Particular backing structure or composition
- Y10T 428/23986: With coating, impregnation, or bond
- Y10T 428/23993: Composition of pile or adhesive
- A47G: HOUSEHOLD OR TABLE EQUIPMENT (book-ends A47B5/00; knives B26B)
- B05C: APPARATUS FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL (spraying apparatus, atomising apparatus, nozzles B05B; plant for applying liquids or other fluent materials to objects by electrostatic spraying B05B5/08)
- B05D: PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL (conveying articles or workpieces through baths of liquid B65G, e.g. B65G49/02)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- D05C: EMBROIDERING; TUFTING (making non-woven fabrics D04H; sewing D05B)
- D06N: WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D10B: INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

A dimensionally stable universal floor covering includes a tufted textile substrate and a reinforcement layer to provide dimensional stability for the entire floor covering. Vacuum, mixing, and injection of compressed air assists in preparing an adhesive and fiber composition to be in the preferred condition and position before the application of pressure to form the reinforcement layer. The universal floor covering is selectively cut and transported in a roll for installation, and it can be conveniently recycled if necessary.

## Claims

### Claim 1

A method of manufacturing a universal floor covering which can be used as either a broadloom or modular floor covering, the method comprising the steps of:
selectively manufacturing either a broadloom or modular floor covering from a group of design components including a tufted textile substrate having a primary backing substrate extending in a first direction and a plurality of yarns tufted through the primary backing substrate, the primary backing substrate having a face side and a back side opposite the face side, a portion of each yarn forming a stitch portion having an end that is located on the back side of the primary backing substrate, and an interstitial space existing between the ends of stitch portions;
said group of design components further including a composition pool having a mixture of adhesive and reinforcement fibers, and said group of design components being collectively and individually designed to have desired performance characteristics;
moving the tufted textile substrate relative to an applicator and providing space between the stitch portions of the yarns and the applicator;
applying pressure in a controlled manner between the applicator and tufted textile substrate and forcing the adhesive and reinforcement fiber composition in a second direction that is toward the back side of the primary backing substrate;
aligning the reinforcement fibers to lay predominantly in the first direction such that the reinforcement fibers form a reinforcement layer of fibers that is substantially parallel to the first direction for providing dimensional stability for the entire floor covering and for forming a universal floor covering that can be used as either a broadloom or modular floor covering;
applying a vacuum to the composition pool before aligning the reinforcement fibers to lay predominantly in the first direction;
curing the universal floor covering; and
selectively cutting the universal floor covering depending on whether it is desired to install a broadloom or modular floor covering, and rolling the cut universal floor covering into a roll for shipment and installation.

### Claim 2 (depends on 1)

The method of manufacturing a floor covering according to claim 1 further comprising selectively cutting the universal floor covering for forming multiple locking patterns at designated intervals along the length of the floor covering.

### Claim 3 (depends on 1)

The method of manufacturing a floor covering according to claim 1 further comprising selectively cutting the universal floor covering at designated intervals along the length of the floor covering.

### Claim 4 (depends on 1)

The method of manufacturing a floor covering according to claim 1 further comprising selectively operating the vacuum for causing the movement of fibers into the spaces between the stitch portions before applying pressure between the applicator and tufted textile substrate.

### Claim 5 (depends on 1)

The method of manufacturing a floor covering according to claim 1 further comprising mixing the adhesive and reinforcement fibers before aligning the fibers to lay predominantly in the first direction.

### Claim 6 (depends on 1)

The method of manufacturing a floor covering according to claim 1 further comprising forming a cushion or friction layer on the reinforcement layer of fibers before cutting the universal floor covering.

### Claim 7 (depends on 1)

The method of manufacturing a floor covering according to claim 1 further comprising forming a cushion or friction roll the same length and width as the universal floor covering.

### Claim 8

A method of manufacturing a universal floor covering which can be used as either a broadloom or modular floor covering, the method comprising the steps of:
selectively manufacturing either a broadloom or modular universal floor covering from the same group of design components including a tufted textile substrate having a primary backing substrate extending in a first direction and a plurality of yarns tufted through the primary backing substrate, the primary backing substrate having a face side and a back side opposite the face side, a portion of each yarn forming a stitch portion having an end that is located on the back side of the primary backing substrate, and an interstitial space existing between the ends of stitch portions; and the characteristics of each design component, including a length of the fibers, a diameter of the fibers, a viscosity of the adhesive, a porosity of the fiber and the adhesive, being selected to meet desired performance characteristics;
selecting an equipment arrangement for applying a pool of adhesive and reinforcement fibers to said tufted textile substrate;
conditioning the adhesive and fibers to assist in preparing the adhesive and fibers to be in a desired condition and location in the pool of adhesive and fibers;
moving the tufted textile substrate relative to an applicator and applying pressure in a controlled manner between the applicator and tufted textile substrate and forcing the adhesive and reinforcement fibers in a second direction that is toward the back side of the primary backing substrate;
aligning the reinforcement fibers to predominantly lay in the first direction such that the reinforcement fibers form a reinforcement layer of fibers that is substantially parallel to the first direction for providing dimensional stability for the entire floor covering and for forming a universal floor covering that can be used as either a broadloom or modular floor covering;
applying a vacuum to the pool of adhesive and reinforcement fibers before completing the alignment of the reinforcement fibers;
curing the universal floor covering; and
selectively cutting the universal floor covering depending on whether it is desired to have a roll of broadloom floor covering, a roll of modular floor covering, or a combination roll having both broadloom and modular floor coverings; and rolling the universal floor covering into a roll for shipment and installation.

### Claim 9 (depends on 8)

The method of manufacturing a universal floor covering according to claim 8 further comprising using the vacuum to move fibers into the spaces between the stitch portions and applying pressure between the applicator and tufted textile substrate to form the layer of reinforcement fibers.

### Claim 10 (depends on 8)

The method of manufacturing a universal floor covering according to claim 8 further comprising applying the vacuum to move adhesive into the back side of the primary backing substrate.

### Claim 11 (depends on 8)

The method of manufacturing a universal floor covering according to claim 8 further comprising selectively mixing the pool of adhesive and reinforcement fibers, selectively injecting air into the pool of adhesive and reinforcement fibers, or selectively applying a vacuum to the pool of adhesive and reinforcement fibers.

### Claim 12 (depends on 8)

The method of manufacturing a universal floor covering according to claim 8 wherein the equipment arrangement includes engaging the applicator with the pool of adhesive and reinforcement fibers or engaging the applicator with the tufted textile substrate, and wherein the applicator applies pressure in a controlled manner for causing the adhesive and reinforcement fibers to move toward the backside of the primary facing substrate.

### Claim 13 (depends on 8)

The method of manufacturing a universal floor covering according to claim 8 further comprising selectively cutting the universal floor covering by forming multiple locking patterns at designated intervals along the length of the floor covering or by cutting the universal floor covering at designated intervals along the length of the floor covering.

### Claim 14 (depends on 13)

The method of manufacturing a universal floor covering according to claim 13 further comprising providing at least one cushion or friction layer on the reinforcement layer of fibers, said layer is formed and cut either with the cutting of the universal floor covering or said layer is formed and cut from a cushion or friction roll to match the cuts on the universal floor covering.

### Claim 15 (depends on 8)

The method of manufacturing a universal floor covering according to claim 8 wherein the adhesive is dissolvable for allowing recycling of the floor covering when necessary by dissolving the adhesive between the reinforcement layer of fibers and the backing substrate for allowing the yarns, textile substrate, reinforcement fibers, and adhesive to be separated and recycled.