Note: Descriptions are shown in the official language in which they were submitted.
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LOW WEIGHT CUSHIONED CARPET, CARPET TILE AND METHOD
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of and claims priority to U. S.
Patent
Application Serial Number 09/587,654, filed June 5, 2000, and hereby
incorporated by
reference.
FIELD OF THE INVENTION
The present invention relates to cushioned, foam backed, or cushion backed
surface
covering, wall covering, floor covering, flooring material, carpet, carpet
tile, or the like,
and more particularly, to a low weight, cushioned carpet, carpet tile and
method. A
process and apparatus fox forming the cushion backed floor covering, carpet or
carpet tile
of the present invention are also provided.
BACKGROUND OF THE INVENTION
As described in U. S. Patent Nos. 4,522,857, 5,540,968, 5,545,276, 5,948,500,
and
6,203,881 (all hereby incorporated by reference herein) carpet and carpet
tiles having
cushioned backings are well known to those of skill in the art. As described
in the
5,948,500 patent and as shown herein, an example of a tufted carpet product is
illustrated
in FIG. 1A and an example of a bonded carpet product is illustrated in FIG.
1B.
In the tufted carpet of Figure 1A, a primary carpet fabric 12 is embedded in
an adhesive
layer 16 in which is embedded a layer of glass scrim or non-woven material. A
foam
base composite 19 is likewise adhesively bonded to the adhesive layer 16. In
the tufted
carpet illustrated in FIG. 1A, the primary carpet fabric 12 includes a loop
pile layer 20
tufted through a primary backing 22 by a conventional tufting process and held
in place
by a pre-coat backing layer of latex 24 or other appropriate adhesives
including a hot
melt adhesive or the like. The foam base composite 19 of the tufted carpet
product
includes an intermediate layer 26 molded to a layer of urethane foam 28 as
illustrated.
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2
The bonded carpet product (FIG. 1B) employs the same type of foam base
composite 19
adhesively bonded by adhesive laminate layers I6. However, the primary bonded
carpet
fabric 12 has somewhat different components from that of the tufted product in
that it has
cut pile yarns 34 implanted in a PVC, latex, or hot melt adhesive 36 having a
woven or
non-woven reinforcement or substrate layer 38 of fiberglass, nylon,
polypropylene, or
polyester.
The practice utilized in forming the product disclosed in the 4,522,857 patent
and other
lmown products involves pre-forming and curing the foam base composite 19 of
urethane foam and backing material by practices such as are disclosed in U.S.
Pat. Nos.
4,171,395, 4,132,817 and 4,512,831, to Tillotson (all hereby incorporated by
reference
herein). As described in these patents, only after this foam base composite is
formed and
cured to some degree as a modular component, is it Laminated to the carpet
base.
As described in the above-mentioned 5,948,500 patent, the cost associated with
such
modular formation and assembly practices may be reduced by a simplified
operation in
which a primary carpet fabric, either with or without a stabilizing layer of
scrim or the
like, is laid directly into a polyurethane-forming composition and thereafter
curing the
polyurethane. The process can be made even more efficient if the polyurethane-
forming
composition requires no pre-curing prior to joining the carpet base.
Prior to the invention described ii1 the 5,948,50G patent, the known processes
direc~eu to
the application of the polyurethane cushioned backings to fabric substrates
relied on the
extremely close control of temperature in both the polyurethane composition
and the
adjoined fabric layer to effect stability through pre-cure of the polyurethane
prior to
lamination of the primary carpet to form a composite structure. Such pre-cure
had been
largely considered necessary in order to yield a stable foam structure to
which the
primary carpet backing could be applied. The application of heat to the
polyurethane
composition prior to joiner of the heated fabric backing caused polymer cross
linking
which had been thought to be necessary to stabilize the foam mixture to a
sufficient
degree to prevent the collapse of the foam.
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3
The invention described in the 5,948,500 patent also provides a particularly
simple
composite structure amendable to in-situ formation of a stable cushion carpet
composite
which is not believed to have been previously utilized. Specifically, it had
not been
previously recognized that a single process could be used to bring all the
layers of the
cushioned carpet composite together by laying a primary carpet fabric, either
with or
without some degree of preheat, directly into a mechanically frothed
polyurethane-
forming composition prior to curing the polyurethane and without an
intermediate layer
of material.
As indicated, the prior art carpet forming processes typically required the
separate
formation of a foam base composite having a backing layer and a layer of
urethane foam.
The backing layer is then used as an intermediate layer to which a primary
carpet fabric
and reinforcing layer can be adhesively bonded.
As described in the 5,948,500 patent, the base of the primary carpet fabric is
adhesively
bonded to a layer of non-woven glass reinforcement material to form a
preliminary
composite. A puddle of polyurethane-forming composition is simultaneously
deposited
across a woven or non-woven backing material. The preliminary composite and
the
polyurethane-forming composition are thereafter almost immediately brought
together
with the preliminary composite being laid into, and supported by, the
polyurethane-
forrning puddle. The entirE 5imc'tui'e is then heated to cure ~im j~~iy ~.~~
c~iialm i~mi~is
composition. The preliminary composite may be slightly heated to about 120
degree F to
improve heating efficiency although the process may likewise be carried out
without
such preheating.
A superior cushion backed carpet tile or modular cushion back carpet tile on
the market
today, for example, sold under the trademark Comfort Plus~ by Milliken &
Company of
LaGrange, Georgia has a primary carpet fabric with a face weight of about 20
to 40
oz/yd2, a hot melt layer of about 38 to 54 oz/yda, a cushion of about 0.10 to
0.2 inches
thick, a weight of about 28-34 oz/yda, and having a density of about 18 lbs.
per cubic
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4
foot, and an overall product height of about 0.4 - 0.8 inches. This superior
cushion back
carpet tile provides excellent resilience and under foot comfort, exhibits
performance
characteristics that rate it for very heavy commercial use, and has achieved a
notable
status throughout the industry as having excellent look, feel wear, comfort,
and cushion
characteristics, performance, properties, and the like. Such a superior
cushion backed
carpet tile is relatively expensive to produce due to the high quality and
quantity of
materials utilized.
Although attempts have been made at reducing the cost of floor coverings or
carpet by
using lower quality materials, such attempts have not been particularly
successful. Low
quality products tend to have a less than desirable look, feel, wear, comfort,
cushion, and
the like. Hence, such products have not been accepted in the industry and have
failed
commercially.
OBJECTS AND SUMMARY OF THE PRESENT INVENTION
In view of the foregoing it is a general object of the present invention to
provide a low
weight foam backed or cushion backed surface covering, wall covering, floor
covering,
flooring material, carpet, or carpet tile.
It is a further object of the present invention to provide a carpet or carpet
tile having a
low face weight.
It is another object of the present invention to provide a carpet tile having
a carpet with a
face iyeight of less than or equal to about 15 oz/yd2.
. ~ -
It is another object of the present invention to provide a carpet tile having
a resilient or
hot melt layer of less than or equal to about 50 oz/yd2.
It is yet another object of the present invention to provide a carpet tile
having a
lightweight cushion.
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It is a further object of the present invention to provide a carpet tile
having a lightweight
cushion of about 0.04 to 0.12 inches thick, preferably 0.04 - 0.09 inches
thick.
It is still another object of the present invention to provide a carpet tile
having a
5 lightweight cushion with a density of less than or equal to about 20 lbs.
per cubic foot.
It is yet another object of the present invention to provide a carpet tile
having a
lightweight cushion with a density of about 13 - 16 lbs. per cubic foot.
It is a fizrther object of the present invention to provide a carpet tile
having a light weight
cushion with a weight of less than or equal to about 26 oz/yd2.
It is a further object of the present invention to provide a low weight
modular carpet tile
having resilience and under foot comfort.
It is still another object of the present invention to provide a low weight
modular carpet
tile exhibiting performance characteristics that rate it for heavy commercial
use.
It is a further object of the present invention to provide a method of forming
a low
weight surface covering, wall covering, flooring, carpet, carpet composite,
carpet tile, or
the like.
It is another object of the present invention to provide a method of forming a
low weight
modular carpet tile having resilience, under foot comfort, and performance
characteristics that rate it for heavy commercial use.
It is an object of the present invention to provide a low weight cushioned
carpet
composite or tile wherein a reinforcement layer is disposed, at least
partially, within a
polymer mass which is adjacent to a primary carpet with such primary carpet
being laid
in-situ into a puddle of the polymer which forms the cushion.
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6
It is a related object of the present invention to provide a low weight
cushioned carpet
composite or tile wherein a primary carpet fabric is joined to a reinforcement
layer and
laid in-situ into a polyurethane-forming composition which has not undergone a
pre-cure
operation.
It is a further obj ect of the present invention to provide a process for the
formation of a
low weight cushioned carpet composite or tile wherein a reinforcement layer is
adhered
to the base of a primary carpet fabric, a polyurethane-forming composition is
applied to a
non-woven backing layer, and the primary carpet fabric with the adhered
reinforcement
layer is attached to the polyurethane-forming composition to form the carpet
composite.
It is still a further related obj ect of the present invention to provide a
continuous process
for the in-situ formation of a cushioned carpet composite wherein a
reinforcement layer
is adhered between a primary carpet base and a backing layer through the in-
situ
application of a polyurethane forming composition without the need for an
intermediate
adhesion step.
It is still a fiuther related object of the present invention to provide an
apparatus for
carrying out the continuous in-situ formation of a cushioned carpet composite.
It is yet another object that the low weight carpet composite and low weight
carpet tile of
L11G ~re~~ni in~entiu'ii may~'ne printed witli orientation irrdepC~iuent
designs or desig'ms
having the ability to seam properly without cutting the tiles in register with
the design
and to allow the carpet to be installed monolithically as well as by
conventional quarter
turn "Parquet", or by ashler (brick). The preferred installation techniques
are monolithic
or ashler with or without floor adhesives.
In accordance with an exemplary embodiment of the present invention, a low
weight
modular carpet composite which may be cut to form low weight modular carpet
tiles
includes a low weight primary carpet or greige carpet having, for example, a
face weight
of less than or equal to about 15 oz/yd2, a hot melt layer of less than or
equal to about 50
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7
oz/yd2, and a lightweight cushion of about 0.04 - 0.12 inches thick. The
cushion may
have a density of about 13 - 16 lbs. per cubic foot or less.
Such a low weight modular carpet composite or low weight modular carpet tile
has
unexpectedly been found to have excellent look, wear cushion, resilience,
under foot
comfort, and exhibits performance characteristics that rate it for heavy
commercial use.
Hence, such a low weight carpet composite or low weight carpet tile may be
used in
place of standard weight cushion backed or hard backed carpet tile, or
broadloom thus
reducing cost, reducing material requirements, reducing weight, reducing
energy
requirements, reducing environmental impact, and the like.
In accordance with a particular example of the present invention, a low weight
modular
carpet composite is cut into modular carpet tiles or carpet squares, for
example, 18 inches
X 18 inches, 36 inches X 36 inches, 50 cm X 50 cm, 1 meter X 1 meter, 48
inches X 48
inches, or the like.
Also, the low weight carpet composite or low weight carpet tile of the present
invention
may be installed on site or on flooring by all of the conventional
installation techniques
as well as can be constructed for adhesive-free installation, self stick, or
the like.
Also, the low weight carpet composite and low weight carpet tile of the
present invention
t~iuy 'ue painted with orientation independent desigii~ c~f ucSfylS flatV~tl~
viia aviiiiy i0
seam properly without cutting the tiles in register with the design and to
allow the carpet
to be installed monolithically as well as by conventional quarter turn
"Parquet", or by
ashler (brick). The preferred installation techniques are monolithic or ashler
with or
without floor adhesives.
In accordance with the present invention, it has been unexpectedly discovered
that a
carpet composite or carpet tile having excellent look, feel, wear, resilience,
and under
foot comfort and exhibiting performance characteristics that rate it for heavy
commercial
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use can be formed by combining a low weight primary carpet with a hot melt or
resilient
layer and a lightweight cushion.
In accordance with the present invention, a low weight modular carpet tile is
provided
having an overall height of about 0.20 to 0.5 inches thick depending on the
construction
of the carpet tile (the number of layers or components) and which can be cut
in any
conventional shape or size.
The low weight carpet composite of the present invention is especially adapted
to be cut
for use as low weight modular carpet tiles, but also finds applicability as
other carpet or
flooring, such as, carpet, broadloom area rugs, runners, floor mats, or the
like.
It is a feature of the present invention to provide a low weight, cushioned
carpet
composite or carpet tile including a primary carpet fabric in laminar relation
to a
reinforcement layer wherein such reinforcement layer is at least partially
embedded in a
polyurethane foam layer which is disposed adjacent to a non-woven backing
layer. The
reinforcement layer may be bonded to the base of the primary carpet fabric by
the
polyurethane foam or by a separate adhesive.
It is a feature of the present invention to provide a low weight, cushioned
carpet
composite or carpet tile including a primary carpet fabric in laminar relation
to a
polyurethane foam layer wl~ici~ is ui~pu~ed adjacem W a uon-woven ba.ckii g
gayer.
It is a feature of the present invention to provide a low weight, cushioned
carpet
composite or carpet tile including a primary carpet fabric in laminar relation
to a
reinforcement layer and a polyurethane foam layer. The reinforcement layer may
be
bonded to the base of the primary carpet fabric by the polyurethane foam or by
a separate
adhesive.
It is a further feature of the present invention to provide a process for
forming a
cushioned carpet composite including the simultaneous continuous steps of
adhering a
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9
woven or non-woven reinforcement material to the base of a primary carpet
fabric;
depositing a puddle of a polyurethane-forming composition across a backing
layer or
support structure and laying the primary carpet fabric and adhered
reinforcement
material into the puddle of polyurethane-forming composition deposited on the
backing
layer.
It is a further feature of the present invention to provide a process for
forming a
cushioned carpet composite including the steps of adhering a woven or non-
woven
reinforcement material to the base of a primary carpet fabric and adhering a
polyurethane
foam and backing layer to the reinforcement material.
It is a further feature of the present invention to provide a process for
forming a
cushioned carpet composite including the simultaneous continuous steps of
forming a
primary carpet fabric; forming a polyurethane foam layer, and adhering the
primary
carpet fabric to the polyurethane foam layer.
It is another feature of the present invention to provide a single step
process for forming
a cushioned carpet composite including applying a polyurethane-forming
composition
adjacent a primary carpet fabric and a non-woven backing layer with the
polyurethane-
forming composition at least partially holding an intermediate layer of
reinforcement
material.
It is yet another feature of the present invention to provide a process for
forming a
cushioned carpet composite including applying a polyurethane-forming
composition
adjacent a primary carpet fabric with the polyurethane-forming composition at
least
partially holding an intermediate layer of reinforcement material.
It is still another feature of the present invention to provide a process for
forming a
cushioned carpet composite including applying a polyurethane-forming
composition
adjacent a primary carpet fabric and a non-woven backing layer
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It is yet a further feature of the present invention to provide an apparatus
for use in the
continuous in-situ formation of a cushioned carpet composite wherein the
apparatus
includes a polymer application unit for depositing a polyurethane-forming
composition
or other suitable polymer in combination with an adhesive application
apparatus for
5 adhering a reinforcement layer to the base of a primary carpet fabric. The
polymer
application unit and the adhesive application unit being simultaneously
operable in
controlled relation to one another such that the primary carpet with the
adhered
reinforcement layer may be laid directly into the polymer.
10 It is yet a further feature of the present invention to provide an
apparatus for use in the
formation of a cushioned carpet composite wherein the apparatus includes a
polymer
application unit for depositing a polyurethane-forming composition or other
suitable
polymer to the base of a primary carpet fabric.
It is yet a further feature of the present invention to provide an apparatus
for use in the
formation of a cushioned carpet composite wherein the apparatus includes an
adhesive
application apparatus for adhering a reinforcement layer to the base of a
primary carpet
fabric.
In accordance with one aspect of the present invention, a cushioned carpet,
composite, or
tile is provided. The cushioned carpet includes a primary carpet having a
primary base
anu a piuraiity of piie-forming yaL~~s p~°ojecting uutW a~itiy iro~ii
one siua. n iaycr ~f
reinforcement material is bonded to the primary base on the side away from the
pile-
forming yarns. The reinforcement material is adjacent to, and embedded at
least partially
in, a cushion layer of polymer such as polyurethane. There is preferably no
additional
adhesive between the cushion layer and the layer of reinforcement material. An
optional
backing material is preferably disposed on the underside of the cushion layer.
The
backing material may include an adhesive backing on the side away from the
cushion
layer.
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In accordance with one aspect of the present invention, a cushioned carpet,
composite, or
tile is provided. The cushioned carpet includes a primary carpet having a
primary base
and a plurality of pile-forming yarns proj ecting outwardly from one side. A
layer of
reinforcement material is bonded to the primary base on the side away from the
pile-
s forming yarns. The reinforcement material is adjacent to a cushion layer of
polymer
such as polyurethane. An optional backing material is preferably disposed on
the
underside of the cushion layer. The backing material may include an adhesive
backing
on the side away from the cushion layer.
In accordance with one aspect of the present invention, a cushioned carpet,
composite, or
tile is provided. The cushioned carpet includes a primary carpet having a
primary base
and a plurality of pile-forming yarns proj ecting outwardly from one side. A
cushion
layer is bonded to the primary base on the side away from the pile-forming
yarns. A
reinforcement material may be embedded in the cushion layer of polymer such as
polyurethane. The cushion layer may be bonded to the primary carpet by a layer
of hot
melt. An optional backing material is preferably disposed on the underside of
the
cushion layer. The backing material may include an adhesive backing on the
side away
from the cushion Layer.
In accordance with another aspect of the present invention, a process for
making a
cushioned carpet is provided. The process involves obtaining a primary carpet
fabric
comprising a plurality ofpiie-r''or~niug yarns extending ~uiWc~tuiy Mvxl3 umc
Side vi a
primary base. A layer of reinforcement material is adhered to the primary
carpet fabric
on the side, from which the pile-forming yarns do not extend, thereby forming
a
preliminary composite. A puddle of polymer such as a polyurethane-forming
composition is applied to one side of a backing material and preferably
doctored to
desired thickness to form a cushion layer. The preliminary composite is then
adhered to
the cushion layer. Following this mating operation, the carpet is cut to size
or into tiles.
In accordance with another aspect of the present invention, a process for
making a
cushioned carpet is provided. The process involves obtaining a primary carpet
fabric
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comprising a plurality of pile-forming yarns extending outwardly from one side
of a
primary base. A puddle of polymer such as a polyurethane-forming composition
is
applied to one side of a backing material and preferably doctored to desired
thickness.
The primary carpet fabric is then laid into the puddle of polymer without
curing.
Following this mating operation, the polymer is preferably heat cured and the
carpet is
cut into tiles.
In accordance with another aspect of the present invention, a process for
making a
cushioned carpet is provided. The process involves obtaining a primary carpet
fabric
comprising a plurality of pile-forming yarns extending outwardly from one side
of a
primary base. A layer of reinforcement material is adhered to the primary
carpet fabric
on the side, from which the pile-forming yarns do not extend, thereby forming
a
preliminary composite. A puddle of polymer such as a polyurethane-forming
composition is applied to one side of a backing material and preferably
doctored to
desired thickness. The preliminary composite is then laid into the puddle of
polymer
without curing. Following this mating operation the polymer is preferably heat
cured and
the carpet is cut into tiles.
In accordance with still another aspect of the present invention, an apparatus
for use in
forming a cushioned carpet composite is provided, comprising: a reinforcement
bonding
unit fox bonding a layer of reinforcement material to the underside of a
primary carpet
falj't1C to fCii~i Q prelllillnary i~ai~~t ~COrtipGS~i:E; tx YGiyitti-.~i
a~l~iii~.diiiru i,ii'liG, fOr dlJ~.D8~~:31~, a~'
polyurethane-forming composition across the surface of a carrier fabric; a
mating unit for
laying said preliminary carpet composite into said polyurethane-forming
composition;
and means for heat curing the polyurethane-forming composition subsequent to
said
preliminary composite being laid into said polyurethane-forming composition;
wherein
said reinforcement bonding unit, said polymer application and said mating unit
are
operable in a continuous, simultaneous manner.
In accordance with still another aspect of the present invention, an apparatus
for use in
forming a cushioned carpet composite is provided, comprising: a reinforcement
bonding
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13
unit for bonding a layer of reinforcement material to the underside of a
primary carpet
fabric to form a preliminary carpet composite; a polymer application unit for
dispersing a
polyurethane-forming composition across the surface of a carrier fabric; means
for heat
curing the polyurethane-forming composition to form a cushion layer, and a
mating unit
for joining the carpet composite and cushion layer.
In accordance with still another aspect of the present invention, an apparatus
for use in
forming a cushioned carpet composite is provided, comprising: a reinforcement
bonding
unit for bonding a layer of reinforcement material to the underside of a
primary carpet
fabric and to the top side of a cushion layer to form a carpet composite.
In accordance with another embodiment of the present invention, a modular
carpet tile is
manufactured by:
tufting broadloom at a weight of 15 oz/yd2 or less,
printing a design in broadloom form,
applying a cushion backing system, and
cutting into square tiles.
The low weight modular carpet tile of the present invention is aesthetically
pleasing and
exhibits performance characteristics that rate it for a heavy commercial
application. The
combination of a low weight (<15 oz/ydz) tufted carpet, hot melt layer, and
cushion
b~,:~un b ;~1;,~ Yrov;;s r:;s~lic~~:,c and un4er-font cor.7fvi~.
The low weight carpet, composite, and tile of the present invention is
especially suited
for broadloom because of
a. Tufted construction
b. ' Applied design
c. Attached cushion backing
The low weight carpet, composite, and tile of the present invention is well
adapted for
modular applications because of:
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14
a. Post applied design
b. Tufted construction
c. Cushion backing
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is a cut-away view of a tufted carpet with a cushioned composite
structure.
FIG. 1B is a cut-away side view of a bonded carpet incorporating a cushioned
composite
structure.
FIG. 2 is a schematic view illustrating an exemplary embodiment of the
apparatus and
process of the present invention.
FIG. 3A is a cut-away side view of a tufted carpet incorporating a structure
formed by
the apparatus and process of the present invention as illustrated in FIG. 2.
FIG. 3B is a cut-away side view of a bonded carpet incorporating a structure
formed by
the apparatus and process of the present invention as illustrated in FIG. 2.
FIG. 4A is a cut-away side view of an alternative embodiment of a tufted
carpet having
no reinforcement layer.
FIG. 4B is a cut-away side view of an alternative embodiment of a bonded
carpet having
no reinforcement layer.
FIG. 5 is a schematic view illustrating an alternative apparatus and process
according to
the present invention for forming a cushioned carpet composite without
separate
adhesive bonding between the primary carpet and the reinforcement layer.
FIG. 6A is a cut-away side view of an alternative structure for a tufted
carpet formed by
the apparatus and process illustrated in FIG. 5.
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FIG. 6B is a cut-away side view of an alternative structure for a bonded
carpet formed by
the apparatus and process illustrated in FIG. 5.
5 FIG. 7 is a schematic view illustrating yet another alternative apparatus
and process
according to the present invention for forming a cushioned carpet composite
without
separate adhesive bonding between the primary carpet and the reinforcement
layer as
illustrated in FIGS. 6A and 6B.
10 Figure 8 is a schematic flow diagram of the production of low weight
modular carpet
tiles in accordance with one embodiment of the present invention.
Figure 9 is a tabular representation of the materials, dimensions,
temperatures, and the
like used in the process of Figure 8.
Figures 10 - 18 are cut-away side views of respective tufted and bonded low
weight
carpet, composite, or tiles in accordance with different embodiments or
aspects of the
present invention.
Although Figures 10A and 11 - 18 show a looped pile in the primary carpet and
Figure
l OB shows a bonded primary carpet, it is to be understood that a bonded or
tufted loop
and/ar c~a plle may be uscd a~~d that the pliv, :i x'y ~.'. a»i'1'~~.,." u,
~iii~tG.~i, uj ~a'1, 3.:~u ~i the
like as desired.
Figures 19 and 19A are respective schematic illustrations of alternative
apparatus and
process in accordance with selected embodiments of the present invention.
While the invention will be described and disclosed in connection with certain
preferred
embodiments and procedures, it is by no means intended to limit the invention
to such
specific embodiments and procedures. Rather it is intended to cover all such
alternative
embodiments, procedures, and modifications thereto as may fall within the true
spirit and
scope of the invention as defined and limited only by the appended claims.
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16
DETAILED DESCRIPTION
In accordance with the present invention, a low weight surface covering, wall
covering,
flooring, carpet, floor covering, carpet composite, or modular carpet tile and
method is
provided which is aesthetically pleasing, exhibits performance characteristics
that rate it
for heavy commercial use, has resilience and underfoot comfort, and which may
be dyed,
printed, and installed as can be done with conventional foam backed or cushion
backed
carpet, composite, or tiles.
A schematic view illustrating an exemplary apparatus and process used in
forming the
low weight, cushioned surface covering, wall covering, flooring, floor
covering, carpet
or tile of the present invention is illustrated in FIG. 2. The apparatus is
designated
generally by reference numeral 100. As illustrated, a primary carpet fabric
112 which
may incorporate either a tufted or a bonded configuration (with loop and/or
cut pile) as
described above is drawn from a mounted carpet roll 114. As indicated
previously, the
primary carpet fabric 112 preferably includes a plurality of pile-forming
yarns projecting
outwardly from one side of a primary backing or base. If the primary carpet
112 used in
the present invention is a tufted carpet, its configuration will preferably
conform to that
of the primary carpet 12 illustrated in regard to that in FIG. 1A, while if
the primary
carpet 112 used in the present invention is a bonded product, its
configuration will be
that of the primary carpet 12 illustrated in FIG. 1B. It is contemplated that
the primary
carp°'.- 112 may include ane Or more hacl,rr~b ~i Ja~..~',~ i i.:x'j
:ate.
It is to be understood that, as with the prior art products, wherein the
primary tufted or
bonded carpet fabric 12 may have different embodiments, the component
structure of the
primary carpet fabric is not critical to the present invention. Rather it is
intended that any
low weight (low face weight) primary carpet fabric having a pile forming
portion and a
primary base may be utilized as the primary carpet fabric. By "primary base"
is meant
any single layer or composite structure including, inter alia, the commonly
used layered
composite of primary backing 22 and latex pre-coat 24 previously described in
relation
to the tufted product (FIG. 1A) and the adhesive layer 36 with reinforcement
substrate 38
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17
previously described in relation to the bonded product (FIG. 1B). As will be
appreciated,
the use of polyester in the primary base structure may be desirable due to the
eventual
heat curing such structure may undergo. Other embodiments as may occur to
those of
skill in the art may, of course, also be utilized. For example, in the bonded
product, the
pile forming yarns could be heat tacked to the substrate 38 as described in U.
S. Patent
No. 5,443,881 (hereby incorporated by reference herein) to permit simplified
construction of a primary carpet.
Alternative embodiments including those disclosed in U.S. Pat. No. 4,576,665
to
Machell (incorporated by reference) may likewise be utilized. For example, it
is
contemplated that specialized primary backings such as non-woven structures
comprising fiberglass sandwiched between layers of polyester may be utilized
in the
primary tufted carpet to impart the desired properties relating to stability
thereby
potentially reducing or even eliminating the need for the secondary backing or
the latex
pre-coat presently utilized. Moreover, it is contemplated that if a pre-coat
is to be
utilized, it may be added directly in-line in an operation prior to any
adhesive operation.
With regard to one embodiment, in the tufted carpet of the present invention
(FIG. 3A),
the primary carpet fabric 112 preferably comprises a loop pile layer 120 of
pile-forming
yarns tufted into a primary backing 122 as is well known and held in place by
a pre-coat
of adhesive 124 such as latex or a hot melt adhesive. It is contemplated that
the latex or
hot melt adhesive rnay ~e added in-line after removal fioiii ;hc carpet roil
prior to the
application of any other adhesive as described below. The carpet may be
steamed after
addition of the pre-coat to facilitate subsequent printing operations if
desired to reduce
stresses. The two basic primary backing constructions are woven polypropylene
and
non-woven polyester. Each material may have a variety of construction
characteristics
engineered for a specific end use. The preferred primary backing material is
20 pick per
inch, woven polypropylene, with needle punched nylon fleece_
In accordance with one example of the present invention, the primary carpet
112 is a
loop pile tufted carpet formed by tufting a non-heatset yarn through the
primary backing,
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18
then washing, steaming, drying, and injection dyeing to form, preferably, a
monolithic or
orientation independent design, color, or pattern thereon to form, for
example, a I2 foot
wide primary carpet precursor of loop pile 120 and primary backing 122. By
using non-
heatset yarn, and originally tufting the yarn at a rather long loop length,
the washing,
steaming, drying and dying steps shrink the yarn to form smaller, tighter
loops and
provide a denser surface to the primary carpet precursor. Next, this primary
carpet
precursor is split in half and rolled to form, two separate six foot wide
rolls of split
primary carpet precursor. Next, one roll of the split primary carpet precursor
is used as
carpet 114 in the apparatus of Figures 2 or carpet 314 in Fig. 5 or 7. The
latex pre-coat
or hot melt adhesive coat 124 is added to the back of the primary carpet
precursor to
form a primary carpet fabric 112 in the upper run of the apparatus of Fig. 2
downstream
of the accumulator 150 and upstream of the reinforcement bonding unit 155. For
example, a thin layer of latex pre-coat is applied to the back of the primary
carpet
precursor using a coating roller.
In accordance with one embodiment of the present invention, the primary carpet
precursor (not having a latex pre-coat) is rolled or wound with the primary
backing 122
exposed.
Also, it is contemplated that the apparatus and process of the present
invention may
include the entire assembly process from tufting the yarn in the primary
backing, dying
eiW i.i,til.CU j%alti, id~c~ pre-coating Zhe vu~l~ ~f the prln?di j~'vaui~iu~,
iitji;-i'll~ii Lvc~vlii~ iiiG
fiberglass reinforcing material, foam coating the felt secondary backing,
laminating the
primary carpet, reinforcing fiberglass, and foam cushioning layer, heating or
curing the
laminate, and cutting the carpet composite into carpet tiles, runners, area
rugs, or the like.
Also, it is contemplated that in accordance with the present invention the
process may be
broken down into its respective steps and done in a batch rather than a
continuous mode,
although the continuous mode of operation is preferred. For example, the
primary carpet
may be formed in one operation and placed on rolls. The cushion backing or
foam layer
may be formed in a separate operation and be placed on a roll. The two may be
joined
by a mating unit using an adhesive, hot melt, hot melt with reinforcing layer,
or the like.
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In the bonded carpet of the present invention (FIG. 3B), the primary carpet
fabric 112
preferably comprises a plurality of cut pile yarns 134 implanted in an
adhesive 136 such
as a latex or hot melt adhesive which is laminated to a reinforcement or
substrate layer
138 of a woven or non-woven material including fiberglass, nylon, polyester,
or
polypropylene. It is contemplated that this substrate layer 138 may be pre-
coated with
latex or other thermoplastic polymers to permit melting adhesion with the cut
pile yarns
134 upon the application of heat, thereby potentially reducing or eliminating
the need for
the latex or hot melt adhesive 136.
The yarns 120, 134 may be either spun or filament yarns and are preferably
formed from
a polyamide polymer such as nylon 6 staple, nylon 6 filament, or nylon 6,6
staple, nylon
6,6 filament, available from DuPont Fibers in Wilmington, Del., although other
suitable
natural or synthetic yarns may likewise be employed as will be recognized by
those of
skill in the art. By way of example only and not limitation, other materials,
which might
be used, include polyester staple or filament such as polyethylene
terephthalate (PET),
and polybutylene terephthalate (PBT); polyolefins, such as polyethylene and
polypropylene staple or filament; rayon; and polyvinyl polymers such as
polyacrylonitrile, wool, nylon/wood blends, Lyocell, rayon, saran, acetate,
glass, aramid,
fluorocarbon, Sulfar, acrylic, Pelco, olefin, melamine, polybenzimidazole, and
combinations thereof. A variety of deniers, plies, twist levels, air
entanglement, and
hPatset ch aracteri~tics can be used to construct t:~~, ~.--:~. 't'3 c pr ~,
~~;,d ;~«~-m is nylo~-~ 5,6,
filament, 1360 denier, 1 ply, no twist, no entanglement, and no heatset.
Another yarn is
nylon 6,6, filament, 1350 denier, no ply, nominal twist (0-1 twist), non-heat
set.
In the tufted product, the adhesive pre-coat 124 is preferably styrene
butadiene rubber
(SBR) latex but other suitable materials such as polyvinyl chloride (PVC),
ethylene vinyl
acetate (EVA), polyurethane, acrylic, and hot melt adhesives as axe well known
to those
of skill in the art may likewise be utilized. In the event that a hot melt
adhesive is
utilized, it is contemplated that a reinforcement material such as a glass
scrim could be
directly attached to form a composite laminate without the use of adhesives.
lVloreover,
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as previously indicated, it is contemplated that the adhesive pre-coat 124 may
be entirely
eliminated in the tufted product if the loop pile I20 is tufted in suitably
stable relation to
the primary backing 122. The commonly used hot melts are bitumen, polyolefin-
based
thermoplastic, and polyurethane. The preferred hot melt material is polyolefin
based
5 thermoplastic.
Referring again to FIG. 2, in the potentially preferred practice the primary
carpet fabric
112 is conveyed by means of a plurality of rolls through an accumulator 150 as
is well
known in the art to a reinforcement bonding unit 155. Simultaneously with the
10 conveyance of the primary carpet fabric 112 to the reinforcement bonding
unit 155, a
sheet of reinforcement material 158 is likewise conveyed to the reinforcement
bonding
unit 155. The reinforcement material 158 is preferably fiberglass non-woven
material
such as a 2.0 oz/ydz fiberglass mat or tissue containing a urea formaldehyde
binder
although alternative materials may include woven glass, woven polyester, and
non- ,
15 woven polyester.
At the reinforcement bonding unit 155, an adhesive 160 (FIGS. 3A, 3B) such as
a hot
melt adhesive is preferably applied to the reinforcement material 158 by means
of a film
coater or other such unit as are well knowm. The reinforcement material 158
and the
20 primary carpet fabric 112 are thereafter preferably passed in mating
relation between
joining members such as rolls 163, 165, thereby bonding the reinforcement
material 158
t0 'the iuldC'.rsiv. r' 0~f thv. prii~xui-y t.i3iy.i .~abiiu i i2. Thiit i5,
the reillf(ii:.v.: ie~tt iii~l.t~rlai i~V
is bonded on the side of the primary carpet fabric 112 from which the pile
forming yarns
do not project. The bonding of the reinforcement material 158 to the underside
of the
primary carpet fabric 112 produces a preliminary composite 166 which is
thereafter laid
into a puddle of polymer or foam forming composition such as a polyurethane-
forming
composition as described below.
Although the reinforcement bonding unit 155 is illustrated in its preferred
embodiment
as incorporating a film coater, it is to be understood that alternative
equivalent means
such as application rolls, spray headers and the like may also be utilized. By
way of
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21
example only, and not limitation alternative means for the application of
adhesive 160
are disclosed in U.S. Pat. No. 4,576,665 to Machell.
In the preferred practice, while the preliminary composite 166 is being
formed, a backing
material 170 such as a non-woven backing is passed through a scray 172 to a
polymer
application unit 175 which preferably includes a polymer discharge unit 176
and a doctor
blade 177. The backing material 170 is coated with a polymer 178 such as a
polyurethane-forming composition as disclosed more fully below.
In the preferred embodiment, the backing material 170 is woven or non-woven
synthetic
fiber material such as 10% to 100% polyester/polypropylene, preferably 50%
polyester,
50% polypropylene non-woven fibrous material which is available from Spartan
Mills
Company in Spartanburg, S.C. While this represents the backing material of
preference,
it is to be understood that any number of alternative compositions may
likewise be
utilized as dictated by requirements regarding shrinkage and installation. The
commonly
used secondary backing materials include non-woven polyester, non-woven
polyester
and polypropylene blends, or woven polypropylene. By way of example only, in
instances where very little or no shrinkage may be tolerated, the backing
material may be
up to 100% polyester. Further, while a non-woven backing material may be
preferred, it
is contemplated that either woven or non-woven constructions may be utilized
as can
materials other than polyester, polypropylene, and polyester/polypropylene
such as
ilyi~n, iiu~YgiaSS a,1111 tliC llKG. iilt ihicitness of thv ~aChlll~ matel'lai
1 i V preferetbly
varies in the range of from about 0.01 inches to about 0.19 inches, although a
range of
between about 0.05 inches and 0.12 inches may be most preferred.
As indicated, in the preferred practice, the polymer application unit 175
applies a deposit
of a polymer 178 (FIGS. 3A, 3B) to the backing material 170 after which the
height of
the polymer is doctored to a desired level.
In the preferred practice, the polymer applied is a polyurethane-forming
composition
based on a so-called soft segment pre-polymer of MDI (diphenylinethane
diisocyanate)
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22
or an MDI derivative. The polyurethane-forming composition also preferably
incorporates a silicone surfactant to improve both the frothability and
stability of the
polyurethane layer or "puddle" which is spread across the surface of the
backing material
170. The commonly used foam density is 18 lbs. per cubic foot with a thickness
of
greater than 0.10 inches. The preferred density is 16 lbs. per cubic foot with
a thickness
of 0.06 inches. '
The preferred polyurethane-forming composition for use in the present
invention is
disclosed in U.S. Pat. No. 5,104,693 to Jenkines the teachings of which are
incorporated
herein by reference. Specifically, the preferred polyurethane-forming
composition which
is applied across the surface of the carrier backing 170 includes:
A. At least one isocyanate-reactive material having an average equivalent
weight of~
about 1000 to about 5000;
B. An effective amount of blowing agent; and
C. A polyisocyanate in an amount to provide an isocyanate index of between
about
90 and about 130, wherein at least 30 percent by weight of such polyisocyanate
is a soft
segment pre-polymer reaction product of a stoichiometric excess of
diphenylinethane
diisocyanate (MDI) or a derivative thereof and an isocyanate-reactive organic
polymer
having an equivalent weight of ~~m about 500 f~ anoui 5,000 and whaueizi elm
prepolymer has an NCO content of about 10 to about 30 percent by weight.
The polyurethane-forming composition also preferably contains a silicone
surfactant to
improve frothability and stability in the form of an Organo-silicone polymer
such as are
disclosed generally in U.S. Pat. No. 4,022,941 to Prokai et al. the teachings
of which are
incorporated herein by reference. Specifically, the preferred surfactant is
preferably a
linear siloxane-polyoxyalkylene (AB) block copolymer and specifically a
polyalkyleneoxidemethylsiloxane copolymer. One such silicone surfactant which
is
particularly useful is available under the trade designation L-5614 from OSI
Specialties,
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23
Ine. whose business address is believed to be 6525 Corners Parkway, Suite 311,
Norcross, Ga. 30092.
A sufficient level of the silicone surfactant is used to stabilize the cells
of the foaming
reaction mixture until curing occurs to allow the preliminary composite 166 to
be laid
into the uncured polyurethane-forming composition puddle without destabilizing
the
layer of such polyurethane-forming composition disposed across the surface of
the
backing material 170. In general, the silicone surfactants are preferably used
in amounts
ranging from about 0.01 to about 2 parts per hundred parts by weight of
component (A)
and more preferably from about 0.35 parts to about 1.0 parts by weight of
component (A)
and most preferably from about 0.4 to 0.75 parts per hundred parts by weight
of
component (A).
As previously indicated, after disposition of the polymer across the backing
material 170
the layer or "puddle" of polymer deposited is preferably doctored to a pre-
determined
height by means of a doctor blade located at the polymer application unit 175.
While a
simple mechanical doctor blade is preferred, alternative equivalent means such
as an air
knife or the like may also be used. Such an air knife is disclosed, for
example, in U.S.
Pat. No. 4,512,831 to Tillotson (hereby incorporated by reference herein).
In one embodiment of the present invention, the primary carpet fabric 112
which is
preferably joined to reinforcEtncmt nnaterial loo to forrt~ the Y~"li~~~i~~~y
~or~~r~s~~~ 1~~ is
laid directly into the polyurethane-forming composition immediately after it
is doctored
to the appropriate level without any need to significantly heat either the
preliminary
composite 166 or the polyurethane-forming composition. Accordingly, the
preliminary
composite 166 and the backing material 170 with the applied polyurethane-
forming
composition may be simultaneously delivered at room temperature to a mating
roll 180
immediately following the application and doctoring of the polyurethane-
forming
composition. As will be appreciated, this avoidance of lag time between
formation of the
components of the cushioned carpet composite permits highly efficient
processing
readily controllable either manually or by computer control means (not shown)
as are
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24
well known to those of skill in the art. In the preferred process, the
preliminary
composite 166 may be slightly preheated to improve operating control during
lamination
and curing but such preheat is not essential to formation of the desired
product.
In the illustrated and preferred embodiment of the carpet, the process
described above
results in the layer of reinforcement material 158 being laid adjacent to and
at least
partially embedded in the layer of polyurethane 178. That is, the
reinforcement material
158 is preferably in intimate contact with the polyurethane 178 such that the
polymer
material is bonded to the reinforcement material and will hold the
reinforcement in place.
Once the preliminary composite 166 has been laid into the polyurethane-forming
composition, the resulting composite may be heated in a heating unit 182 by
means of
conduction, radiant, or convection heaters as are well known in the art.
Contact
conduction heaters may be preferred. Such heating may be carried out at a
temperature
of between about 250°F and about 325°F for between about 2
minutes and 8 minutes.
The resulting cured foam or foam cushion layer (FIGS. 3A, 3B) which is
produced
thereby has a density of between about 12 pounds per cubic foot and about 20
pounds
per cubit foot preferably between about 14 pounds per cubic foot and about 16
pounds
per cubic foot, and more preferably about 16 pounds per cubic foot.
Following the heat curing operation, the cushioned carpet composite which is
formed
may be ~a~~sd over a tuli~iTeC~lOrlll heat/ Sfruii.G a JJ Siii.it dS ci
tii&~C.. ii~ater oT 1.711 :iv°.~.t:.i
at about 400° F to fuse any outstanding fibers on the backing material
170 into a Booth
surface. The carpet composite, which is formed, will thereafter be rolled,
cut, sliced, or
the like. When making carpet tiles, it is preferred that it be cut into carpet
tiles almost
immediately (rather than rolled) to avoid any undesired cupping or curl. After
the carpet
tiles are cut from the composite, they are stacked, packaged and stored or
shipped to the
customer or store.
It will be appreciated that a number of alternative practices may be
incorporated into the
present invention yielding slightly different products. By way of example
only, the
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reinforcement material 158 may be left completely out of the process thereby
making the
use of the adhesive application apparatus 155 and adhesive 160 completely
unnecessary.
In such instances, the primary carpet fabric may be laid directly into the
polyurethane-
forming composition thereby yielding a composite structure as illustrated in
FIGS. 4A
5 and 4B with the polyurethane 278 immediately adjacent to the primary carpet
fabric 212
and as described in U.S. Patent No. 6,203,881 hereby incorporated by
reference.
In accordance with another embodiment, when the cushion layer is preformed
rather than
formed in-situ, a hot melt layer may be used to mate the primary carpet to the
cushion
10 layer with or without the reinforcement material (Fig. 12). Such a process
described in
U.S. Patent No. 4,522,857 hereby incorporated by reference.
~ yet another potential alternative, the backing 170, 270 may have an adhesive
quick
release backing attached to the face to which the polyurethane-forming
composition is
15 not applied. As will be appreciated, such a quick release backing will
permit the carpet to
be readily installed and removed without damaging the polyurethane cushion
178, 278.
Moreover, it is contemplated that in some instances the backing 170, 270 might
be
completely eliminated such that the polyurethane cushion 178, 278 would
directly
contact the flooring as disclosed in relation to U.S. Pat. No. 4,286,003 which
is
20 incorporated herein by reference. Also, an adhesive-free carpet and method
is described
for example in co-pending U. S. Patent Application Serial No. 09/513,020,
filed
iWviiLQIy LJ, iiuVV~, a~'1~ ~r~titied Adhesive-Fre;; ~;ai-i7et ~~leS ~:uu
Carpei file IiW iaiiwtxiura3
(hereby incorporated by reference herein). It is preferred that cazpet tiles
for adhesive-
free installations have a cup of about 3/16 inch or less and a curl of 1/16
inch or less.
Although it is preferred for the tufted surface covering, tufted low weight
modular carpet
or low weight modular carpet tile of the present invention to have the
following layers:
yarn, primary backing, latex pre-coat adhesive, hot melt adhesive, fiberglass,
polyurethane foam, and felt (Fig. 10A), it is contemplated that one or more of
these
layers rnay be eliminated or substituted for and still provide a low weight
carpet or tile
having the desired properties or characteristics. For example, the latex pre-
coat adhesive
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26
layer may be replaced by a bitumen hot melt layer (Fig. 11), the felt layer
may be
eliminated on a free lay (no floor adhesive) installation product (Fig. 16),
the glass layer
may be eliminated (Fig. 12), or the like.
An alternative process and apparatus for producing a cushioned carpet
composite
according to the present invention is shown schematically in FIG. 5. As
illustrated, a
primary carpet fabric 312 having either a tufted or a bonded configuration is
drawn from
a mounted carpet roll 314, through an accumulator 350, in the same manner
described
above. Simultaneously with the delivery of the primary carpet fabric 312 to
the mating
roll 380, a reinforcement material 358 such as a non-woven glass is delivered
to a
polymer contact roll 360 or similar device such as an extrusion coater. The
polyner
contact roll 360 preferably is in rolling contact with both the surface of the
reinforcement
material 358 as well as with an accumulation of a polymer 378 such as the
polyurethane-
forming composition previously described. The polymer contact roll 360 serves
to pick
up a portion of the polymer 378 and to pass the polymer over and through the
reinforcement material 358.
Simultaneously with the passage of polymer through the reinforcement material
358, a
backing material 370 such as the non-woven polyester/polypropylene described
above is
preferably passed in adjacent mating relation to the polymer-coated
reinforcement
material 358 between the polymer contact roll 360 and a backing material
mating roll
379. A doctor blade 377 serves to control the depth of the polymer which does
not pass
through the reinforcement material 358 into contact with the backing material
370. Thus,
it is to be appreciated that a polymer sandwich structure is formed preferably
comprising
a layer of baclcing material 370, a relatively thin layer of polymer 378 such
as
polyurethane which has been passed through a layer of reinforcement material
358, and a
doctored layer of polyurethane 378 which was not passed through the
reinforcement
material 358. This polymer sandwich structure can thereafter be passed to the
mating roll
380 for joinder with the primary carpet fabric 312 by laying the primary
carpet fabric
312 directly into the doctored layer of polyurethane 378 without any pre-
curing
operation. Thereafter, the composite is heated, cured, and rolled or cut.
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27
A potentially preferred configuration for a resulting tufted carpet composite
is illustrated
in FIG. 6A. As illustrated, the reinforcement material 358 will be at least
partially
surrounded by, and embedded in, the polyurethane 378. As illustrated, it is
contemplated
that the layer of pre-coat may be eliminated in the tufted structure since the
tufts may be
held in place by the polyurethane 378. A potentially preferred configuration
for a
resulting bonded carpet composite is shown in FIG. 6B.
With respect to Figures SA and 18 of the drawings, the reinforcement material
and hot
melt layers can be eliminated simply by not feeding the reinforcement 358
along with the
felt 370 and primary carpet 312.
A further alternative process and apparatus for joining all layers of the
cushioned carpet
composite is illustrated in FIG. 7. As shown, a layer of reinforcement
material 358 is
preferably passed adjacent to a polymer contact roll 360 which is in
simultaneous rolling
contact with both the reinforcement material 358 and a deposit of polymer 378.
The
polymer contact roll 360 serves to spread a portion of the polymer 378 through
the
reinforcement material 358 to create a coating on both sides thereof. The
reinforcement
material 358 with its coating of polymer 378 is then joined in a laminate
structure to the
primary carpet fabric 312 and a layer of bacl~ing material 370 by passage
through the nip
between the doctor blade 377 and backing material mating roll 379. Thereafter,
the
composite is heated, cured, and rolled or cut. This practice will yield a
bonded carpet
composite structure substantially similar to those which are illustrated in
FIGS. 6A and
6B.
In accordance with one aspect of the present invention, the designs that are
printed on the
low weight modular carpet or carpet tile are preferably characterized as
orientation
independent or as having the ability to seam properly without cutting the
tiles in register
with the design. The techniques used to create these designs make it possible
to install
modular carpet monolithically rather than quarter tum or ashler. The commonly
used
techW ques of modular carpet installation such as quarter turn (parquet),
monolithic, and
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28
ashler (brick) may be used to install low weight carpet or carpet tiles of the
present
invention. The preferred technique is monolithic or ashler. Also, a floor
adhesive may
or may not be used depending on whether the carpet or tile is designed for
adhesive-free
installation or conventional adhesive installation. Also, the carpet tile may
be self stick
and contain an adhesive quick release backing attached to the face of the
backing 170,
270 opposite the polyurethane foam.
With reference to Figures 19 and 19A of the drawings, the felt and hot melt
layers can be
eliminated by, for example, feeding the primary carpet 314 through an
apparatus similar
to that shown in Fig. 5 of the drawings, except that the carpet is inverted
and the polymer
layer or layers are applied directly to the reinforcement material and/or
lower surface of
the primary carpet.
With respect to Figures 17 and 19A of the drawings, the reinforcement material
such as
glass is eliminated by not feeding the reinforcement material along with the
carpet and
polymer.
In accordance with one example of the present invention, the low weight
modular carpet
tile of Example I below was tested using a hexapod test as described below.
Test Method Conducted
ASTM D-5252 Hexapod Drum Tester
ISO/TR 10361 Hexapod Tumbler
Ratings Based on CRI TM-101 Photographic Scales
,.,:
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29
APPARATUS: WIRA INSTRUMENTATION HEXAPOD
TUMBLER CARPET TESTER
PROCEDURE:
The test specimen was subjected to the reported cycles of "Hexapod" tumbling,
removing the specimen every 2,000 cycles for restoration by vacuuming.
An Electrolux upright vacuum cleaner (Discovery II) was used, making four (4)
forward
and baclcward passes along the length of the specimen.
The samples were assessed using daylight equivalent vertical lighting (1500
lux).
Samples were viewed at an angle of 45 degrees from I %a meter distance,
judging from
all directions.
The samples were also measured for pile height before and after testing to
obtain a pile
height retention value.
TEST RESULTS
Number of Hexapod 4000 12000 Key to Ratings
Cycles
Color Change 3 - 3 5 = Negligible or
4 no change
Pile Height Retention89.4% 74.8% 4 = Slight change
Overall Appearance 4 3 3 = Moderate change
Change
2 = Considerable change
1 = Severe change
The invention may be further understood by reference to the following examples
which
are not to be construed as unduly limiting the invention which is to be
defined and
construed in light of the appended claims.
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EXAMPLE I
A tufted carpet was produced by the apparatus and process as illustrated and
described in
relation to FIG. 2. The carpet produced has the configuration illustrated and
described in
relation to FIG. 3A. The production parameters were as follows:
5 Yarn 15 ounces per sq. yd. nylon 6,6 loop pile continuous
filament
Primary Backing 4 ounces per sq. yd. non-woven polyester
10 Pre-coat 16 ounces per sq. yd. SBR Latex filled with 100 parts
CaCO2.
Hot Melt Adhesive 42 ounces per sq. yd. modified polypropylene
15 Laminate
Reinforcement 2 ounces per sq. yd. Non-woven glass with acrylic binder
Urethane Foam Coverage 20 ounces per sq. yd.
20 Urethane Foam Density 16 pounds per cubic foot
Backing Material 4 ounces per sq. yd. Non-woven (50% polypropylene, 50%
polyester)
25 EXAMPLE II
Construction Tufted, Textured Loop Pile
Face Fiber 100% Milliken Certified WearOn~
Nylon
Soil Protectant MilliGuard~
30 Antimicrobial BioCare~
Dye Method Millitron~ Dye Injection Printing
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Gauge 1/10 in. (39.4/lOcm.)
Rows 14.4/in. (56.7/lOcm.)
Tufts 143.9/sq.in. (2230.3/100
sq.cm.)
Standard Backing PVC-Free UNDERSCORETM
cushion
Nominal Total Thickness 0.34 in. (8.6mm)
Total Weight 99.9 oz./sq.yd. (3,387.4
g./sq.m.)
Tile Sire 36 X 36 in. (914.4 X
914.4mm)
Flammability (Radiant Panel ASTM-E-648)>0.45 (Class I)
Smolce Density (NFPA-258-T or ASTM-E-662)<450
Methenamine Pill Test Self Extinguishing
(CPSC FF-1-70 or ASTM D 2859)
Lightfastness (AATCC 16E) >4.0 at 80 hrs.
Crocking (AATCC 165) >4.0 wet or dry
Static Electricity (AATCC-134) <3.5 KV
20% R.H.,70F
Dimensional Stability - Aachener test<0.2%
(DIN Standard 54318)
Recommended Traffic Heavy Commercial
Recommended Maintenance Millicare~
CR.I Indoor Air Quality Product Type: 12200793
EXAMPLE III
Construction Tufted, Textured Loop Pile
Face Fiber 100% Milliken Certified WearOn~
Nylon
Soil Protectant MilliGuard~
Antimicrobial BioCare~
Dye Method Millitron~
Gauge 1/10 in. (39.4/lOcm.)
Rows 14.4/in. (56.7/lOcm.)
Tufts 143.9/sq.in. (2230.3/100 sq.cm.)
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Standard Backing PVC-Free UNDERSCORETM
cushion
Nominal Total Thickness 0.34 in. (8.6mm.)
Total Weight 99.9 oz./sq.yd. (3,387.4g./sq.m.)
Tile size 36 X 36 in. (914.4 X
914.4mm.)
Flammability (Radiant Panel ASTM-E-648)>0.45 (Class I)
Smoke Density (NFPA-258-T or ASTM-E-662)<450
Methenamine Pill Test Self Extinguishing
(CPSCFF-1-770 or ASTM D 2859)
Lightfastness (AATCC 16E) >4.0 at 80 hrs.
Crocking (AATCC 165) >4.0 wet or dry
Static Electricity (AATCC-134) 20% <3.5 KV
R.H., 70F
Dimensional Stability - Aachener Text <0.2%
(DIN Standard 54318)
Recommended Traffic Heavy Commercial
Recommended Maintenance MilliCare~
CRI Indoor Air Quality Product Type: 12200793
EXAMPLE IV
A tufted carpet is produced by the apparatus and process as illustrated and
described in
relation to FIG. 2. The carpet has the configuration illustrated and described
in relation to
FIG. 3A. The production parameters are as follows:
Yam ' 12 ounces per sq. yd. nylon 6,6 loop pile continuous
filament, white, 1350 denier, not plied, not twisted, not
heat set
Primary Baclcing 4 ounces per sq. yd. non-woven polyester
Pre-coat 16 ounces per sq. yd. SBR Latex filled with 100 parts
CaCO2.
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Hot Melt Adhesive 36 ounces per sq. yd. modified polypropylene
Laminate
Reinforcement 2 ounces per sq. yd. Non-woven glass with acrylic binder
Urethane Foam Coverage 15 ounces per sq. yd.
Urethane Foam Density 16 pounds per cubic foot
Backing Material 4 ounces per sq. yd. Non-woven (50% polypropylene, 50%
polyester)
EXAMPLE V
A tufted carpet is produced by the apparatus and process as illustrated and
described in
relation to FIG. 2. The carpet has the configuration illustrated and described
in relation to
FIG. 3A. The production parameters are as follows:
Yarn 16 ounces per sq. yd. nylon 6,6 loop pile continuous
filament
Primary Backing 2 ounces per sq. yd. non-woven polyester
Pre-coat 14 ounces per sq. yd. SBR Latex filled with 100 parts
CaCO2.
Hot Melt Adhesive 38 ounces per sq. yd. modified polypropylene
Laminate
Reinforcement 3 ounces per sq. yd. Non-woven glass with acrylic binder
Urethane Foam Coverage 12 ounces per sq. yd.
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Urethane Foam Density 14 pounds per cubic foot
Backing Material 2 ounces per sq. yd. Non-woven (50% polypropylene, 50%
polyester)
EXAMPLE VI
A tufted carpet is produced by the apparatus and process as illustrated and
described in
relation to FIG. 5. The carpet has the configuration illustrated and described
in relation to
FIG. 6A. The production parameters are as follows:
Yarn 15 ounces per sq. yd. nylon 6,6 loop pile continuous
filament, white, 1350 denier, not plied, not twisted, not
heat set
Primary Backing 4 ounces per sq. yd. non-woven polyester
Laminate
Reinforcement 2 ounces per sq. yd. Non-woven glass with acrylic binder
Urethane Foam Coverage 36 ounces per sq. yd.
Urethane Foam Density 16 pounds per cubic foot
Bacl~ing Material 4 ounces per sq. yd. Non-woven (50% polypropylene, 50%
polyester)
EXAMPLE VII
A tufted carpet is produced by the apparatus and process as illustrated and
described in
relation to FIG. 19. The carpet has the configuration illustrated and
described in relation
to FIG. 18. The production parameters are as follows:
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Yarn 15 ounces per sq. yd. nylon 6,6 loop pile continuous
filament, wlute, 1350 denier, not plied, not twisted, not
heat set
5 Primary Backing 4 ounces per sq. yd. non-woven polyester
Pre-coat 16 ounces per sq. yd. SBR Latex filled with 100 parts
CaCO2.
10 Reinforcement Material 2 ounces per sq. yd. Non-woven glass with acrylic
binder
Urethane Foam Coverage 20 ounces per sq. yd.
Urethane Foam Density I6 pounds per cubic foot
Comfort Rating
1. Gmax - Gmax simulates footfall onto a surface. The measure is reported as
multiples of "g" (gravities), or Gmax. The lower the value, the lower the
force
upon impact, and the more comfortable underfoot the product feels. The higher
the value, the higher the force upon impact, and the less comfortable the
carpet
feels.
Gmax Test Results
Standard Milliken ComfortPlus~ cushion-backed carpet tile -116
Low weight cushion baclced carpet tile of the present invention -129
Standard commercial broadloom without underlayment -185
Standard hardback carpet tile, such as Everwher a PVC hardback - 227
Resilience Rating
Cushion Resilience - Cushion resiliency measures the rebound percent of a
metal
ball when dropped from a standard height. It shows the shock absorbing
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character of the cushion, which helps reduce visible wear of the carpet face.
The
higher the value, the higher the rebound percent, and the more resilient the
cushion.
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Resilience Results
Standard Milliken ComfortPlus cushion backed carpet tile - 30
Low weight polyurethane cushion baclc carpet tile of the present invention -
27
Standard commercial broadloom without underlayment -17
Standard hardback carpet tile-13
Appearance Retention
Appearance Retention Rating (ARR) - the ARR value is determined by grading
the appearance change of carpet subjected to exposure conditions in accordance
with either the ASTM D-5252 (Hexapod) or ASTM D-5417 (Vettermann) test
method using the number of cycles for short and long-term tests specified.
ARR - Light (short-teen>/=3.0, long-term>/=2.5
ARR - Moderate (short-term>/=3.5, long-term >/=3.0
ARR - Heavy (short-term>/=4.0, long-term >/=3.5
The low weight modular carpet tile of the present invention had an APR of
about 4.0
short term and 3.5 long term.
Durability
The low weight polyurethane cushion back carpet tile of the present invention
is very
durable and can withstand 25,000 cycles or more of the caster chair test
without failure.
In accordance with at least one embodiment of the present invention, the low
face weight
primar'~ carpet preferably has a face weight of less than 15 oz/yd2, more
preferably 12
oz/yda or less.
The low weight carpet tile of the present invention is unexpectedly very
merchantable
and commercially viable due in part to its reduced cost; look, wear, and
cushion
characteristics; seamability; patterned monolithic design; uiuformity of
appearance
between tiles; constant shade; durability; less crush; short pile; dense
surface; and
combinations thereof.
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One method used to achieve sufficient yarn coverage, suitable for patterning
and
resilience in commercial use, on the low face weight carpet tile of the
present invention
is to utilize a singles yarn of sufficient denier, in the range of 1000d and
1400d, in a non-
heatset form. By using non-heatset yarn, the shrinkage which normally takes
place in
heatsetting (typically about 11%), now takes place in the wet processing of
dyeing the
tufted carpet. After dye application, the carpet enters the continuous dye
steamer, where
the yarn bulks (shrinks ~l 1 %) in the formed fabric of the carpet, thus
dramatically
increasing the coverage of the carpet face, lowering the pile height, and
making a much
denser face fabric. The positive result of this post fabric formation
shrinkage is better
carpet performance with low density face weight, and improved aesthetic
appearance due
to the improved coverage.
In accordance with one embodiment of the present invention, it is preferred to
have a pile
height of less than 8/64 inch after dyeing (after heat set).
In accordance with at least one embodiment of the present invention, it is
preferred to use
an open cell foam such as a polyurethane foam in the foam or cushion backing.
The lighter weight and reduced thickness of the tiles allows more tiles to be
added in
each box or on each pallet. Also, each file is easier to handle during
installation, easier
to cut, and easier to bend.
There axe at least four options or examples of the foam cushion to obtain low
weight,
commercially acceptable foam products using polyurethane.
1) Use of standard filled Polyurethane system. One polyurethane foam contains
110
parts of filler and is applied as low a density as 15 #/cu. ft. If the
thickness is in
the range of .04 - .12 and we determine polymer weight only, using the density
and filler levels above, the weight range of the polymer would be 4.32 oz/sq
yd to
12.96 oz/sq yd.
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2) A second option which would also work would be to increase the filler
levels to
190 and reduce the density to 13 #/cu. ft. (Min. which is possible with a
filled
system). At the same thickness limits the polymer weights would then be 2.72 -
8.24 oz/sq. yd.
3) A third option would be to use an unfilled polyurethane (Prime urethane)
system.
High densities such as above are not possible with prime however, they perform
because of the wall structure and the fact that no filler is present If we
consider a
prime to be at 6 #/cu.~ ft. applied at the thickness limits above the polymer
weight
would be 2.88 - 8.64 oz/sq. yd.
4) A fourth option is also possible. Textile Rubber has a polyurethane system
available called "I~angahide" wluch has only 15 parts of a filler material and
is
applied at 6 - 9 lb/cu. ft. density, if a polymer calculation is again made at
the
describe thiclmess limits it would be 4.3 -13.02 oz/sq. yd.
Although the above examples have to do with Polyurethane, a water based foam
system can also be used.
Although it is preferred to print the carpet composite and then cut tiles
therefrom, the
carpet composite may be cut into tiles and then each cut tile may be printed.
For
example, the cut tiles or blanks may be jet dyed or dye injection printed.
This provides
for improved design or pattern registration on the tiles and allows for
monolithic
installation of complex designs.
In one embodiment, the invention relates to a single 1350d, white carpet yarn
that is
tufted into a backing. The face weight is usually about 12 ounces/yd2. The
resulting
face fabric is wealc, and has many "holes" where the backing is visible
through the face.
The face is applied to a cushion backing by a hot-melt resilient layer. The
carpet is
passed through the broadloom Millitron jet dye process, whereby the steam and
dry heat
involved in the dye fixation process shrink the tuft yarns. The shrinkage
results in short,
dense tufts that are durable and have good appearance. The roll is then cut
into tiles and
shipped.
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hl accordance
with at
least one
embodiment,
the low
weight
cushion
backed
carpet
of the
present
invention
provides
for one
or more
of the
following:
Benefits
1. Reduced
Cost
5 2. Underfoot Comfort
3. Performance
Reduced '
Cost
1. Less raw materials - lower pile height
2. Lower processing cost - lower yarn conversion
10 a. No heatsetting
b. No twisting
c. No plying
3. Less dye
a. Lower amount
15 b. Print broadloom and cut
c. 10 gauge
d. Coagulation chemistry - dye concentration at tip
4. No edge trimming required
5 . B acking
20 a. Different backing - polypropylene (woven)
b. Nylon cap (for functionality)
6. Lower foam cost
a. Thinner layer
b. Increased speed down range
25 7. 36" tiles (larger tiles)
8. More yardage can be run before doffing
9. Shipping/packaging - from 80 to 110 tiles per pallet
(low thickness/light
weight)
10. Installation
30 a. Can use brick-laying pattern (lots of patterns)
b. Easier to cut and lift because it is thinner
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Performance
Benefits
1. Long lasting
a. Appearance retention
b. Foam resilience retention
c. Less susceptible to "pulled lines"
2. Highly patterned
3. Vacuums more easily
4. Can use an ashler pattern for laying the tiles
- fewer visible seams
5. Performance
a. Under-foot comfort
b. Resilience/durability improved in high traffic
areas
c. Crush resistance
d. Ergonomics
e. Noise reduction
f. Hides imperfections under carpet
g. Roll resistance reduced
h. Tuft binding
It is, of course, to be appreciated that while several potentially preferred
embodiments
have been shown and described, the invention is in no way to be limited
thereto, since
modifications may be made and other embodiments of the principles of tlus
invention
will occur to those skilled in the art to which this invention pertains.
Therefore, it is
contemplated by the appended claims to cover any such modifications and other
embodiments as incorporate the features of this invention within the true
spirit and scope
thereof.
