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Lightweight Carpet Tile and Method

a carpet tile and lightweight technology, applied in textiles, papermaking, transportation and packaging, etc., can solve the problems of residential carpet tiles that have traditionally added to their manufacturing cost are the use of latex backings and the cost of backing materials, and achieve the effects of minimizing the creation, reducing the expansion or shrinkage, and facilitating the cutting

Inactive Publication Date: 2018-08-23
WALKER PAUL
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

The patent text describes a process for applying polyurethane coating on greige carpets and using inexpensive secondary backings that can be used with sprayed-on adhesives. The resulting carpet has minimal expansion or shrinkage and does not require a separate cushion or pad layer. The polyurethane backing can provide suitable dimensional stability and the fabric can be manufactured with sufficient tuft density for commercial use. The use of appropriate backing fabrics can also help reduce the creation of visual ledges between tiles. Overall, the process allows for easy application and improved stability and comfort of polyurethane-coated carpets.

Problems solved by technology

In this market, there is little demand for plush surfaces that would readily show wear in lanes of traffic.
An aspect of residential carpet tiles that has traditionally added to their manufacturing cost is the use of latex backing and the cost of backing materials.

Method used

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  • Lightweight Carpet Tile and Method
  • Lightweight Carpet Tile and Method
  • Lightweight Carpet Tile and Method

Examples

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Embodiment Construction

[0013]A detailed explanation of a polyurethane coating process is set forth in U.S. Pat. No. 7,638,008, which is incorporated herein in its entirety. The roller coating process of this patent and related improvements as described in U.S. Ser. No. 15 / 782,265, is advantageously used in the manufacture of lightweight carpet products.

[0014]FIG. 1 depicts a sectional view of a loop pile carpet tile 40 with looped bights of yarn 41 penetrating a backing material 42, bound in position with a polyurethane adhesive layer 43, and an attached secondary backing of 44. The carpet density can be substantially less than 3000, or less than 2500, or even less than 2000. Carpet density is calculated using the following formula:

Carpet face weight×36 / carpet pile height=density, measured in ounces per cubic yard

[0015]The pile height is the length of the fiber from tip to the carpet backing. In the above formula, pile height should be represented as a fraction of an inch, reflected in decimal format. For...

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Abstract

A novel carpet tile is provided with a polyurethane adhesive layer resulting in a lightweight product with exceptional dimensional stability.

Description

[0001]This patent application claims priority to U.S. Provisional Application Ser. No. 62 / 460,328, filed Feb. 17, 2017.FIELD OF THE INVENTION[0002]The present invention relates to improved methods for manufacturing lightweight carpet tile products especially suited for the residential market and the structure of those tiles, but also adaptable to commercial use.BACKGROUND OF THE INVENTION[0003]The carpet tile market has evolved into distinct categories for commercial and residential markets. The commercial market for hotels, hospitality facilities, and public buildings is exemplified by high traffic, mostly foot traffic, but also rolling carts and equipment. In this market, there is little demand for plush surfaces that would readily show wear in lanes of traffic. Carpet tiles designed for the commercial market have evolved into largely a low loop pile surface category or in some cases cut / loop with dense cut pile areas, and the structure of these tiles is intended to withstand heav...

Claims

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Application Information

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IPC IPC(8): D06N7/00
CPCD06N7/0086D06N7/0081D06N2201/0254D06N2201/0263D06N2211/066D06N2213/063D06N2213/066D06N2213/068D10B2331/02D10B2321/022D10B2401/08D06N2203/068C09J2203/314C09J7/38Y10T428/14Y10T428/1476
Inventor WALKER, PAUL
Owner WALKER PAUL