Floor covering

Abstract

A method of manufacturing a floor covering comprising a tufted textile substrate and a reinforcing backing system. The backing system comprises an adhesive layer which is adjusted to contain voids. A reinforcing fiber layer is located between the adhesive layer. After drying, the adhesive layer and reinforcing fiber layer are compressed to collapse the voids in the adhesive layer and encapsulate the reinforcing fibers. The reinforcing fiber layer is also moved toward the primary backing substrate and engages the ends of the tufts.

Description

Technical Field

[0001] This disclosure relates to the field of textile floor coverings, such as wide-width carpets and interlocking carpets. More specifically, according to one or more aspects provided herein, this disclosure relates to a floor covering comprising a tufted textile substrate and a reinforcing backing system.

[0002] background

[0003] With the advent of tufting equipment, floor coverings have evolved over time from woven carpets to the tufted carpets used today. Machine tufting begins with a single needle, similar to that of a sewing machine. The needle carries yarn through a backing fabric substrate, forming stitches on the back side adjacent to the substrate. On the front side, loops secure the yarn at a designated height above the backing fabric substrate to form the carpet pile. The tufting yarn and the backing fabric substrate are collectively referred to as the tufted textile substrate.

[0004] The single-needle configuration evolved into a multi-needle parallel operation, which is how tufted carpets are currently manufactured. Using this equipment, tuft widths can reach 16 feet, and when sold in these widths, these carpets are known in the industry as "wide" carpets. This type of carpet is the preferred flooring material for residential and commercial buildings today.

[0005] Modular carpet products (small square carpets) were introduced to address some of the problems encountered with wide-width carpet products. Because individual modules in the unit can be removed and replaced when they get dirty or worn, modular carpets are very useful in applications where wide-width carpets are impractical, such as offices, airports, and other high-traffic areas.

[0006] Both wide-width and small-square rug designs face stability challenges and issues. Wide-width rug designs tend to "creep" without separate reinforcing floor coverings and / or one or more auxiliary backing layers, leading to undesirable growth. Modular small-square rugs with heavy backing layers are rigid. As a result, modular small-square rugs tend to cup or curl. Modular small-square rugs and wide-width rugs present additional challenges due to issues related to variations in thickness and weight. Manufacturers of floor coverings face significant material costs and manufacturing expenses associated with processing and bonding multiple backing layers and / or pre-formed reinforcing layers to the fabric substrate.

[0007] In the carpet industry, it is well known that the machine orientation of a carpet has the greatest impact on dimensional stability. "Machine orientation" is considered to refer to the direction in which the yarn tufts. The yarn forms a series of continuous loops in the machine orientation, which is inherently unstable, especially when exposed to heat and / or moisture. Furthermore, the base fabric tends to shrink more in the machine orientation of the floor cover. Therefore, the machine orientation is almost always the less stable direction for the floor cover.

[0008] The invention described herein relates to U.S. Patents 9,339,136, 9,506,175, 9,681,768, 9,775,457, 9,924,820, 9,926,657, 1,013,2019, and 1,050,1878. This application discloses and claims a method for manufacturing a carpet having a reinforcing backing substrate layer.

[0009] Overview

[0010] This invention includes a floor covering with a universal fiber-reinforced base fabric. The floor covering can be used in wide-width products or any of a variety of modular products. The manufacturing method and the resulting product include a tufted fabric substrate having a main base fabric substrate and multiple yarns of tufted fabric passing through the main base fabric substrate. The main base fabric substrate includes a front side and a back side opposite the front side, with a portion of each yarn forming a stitch on the back side of the main base fabric substrate.

[0011] The manufacturing process begins with adjusting a first adhesive to create multiple voids within it. After adjustment, the adhesive is directed to a first applicator, which applies pressure in a controlled manner to force the adhesive toward the back side of the main backing fabric substrate. The adhesive is pressed into and between stitches located on the back side of the main backing fabric substrate. The movement of the first adhesive is controlled by the first applicator and a vacuum applied to the front side of the main backing fabric substrate. The first adhesive is formed as a first adhesive layer, which is formed along the machine direction.

[0012] The spaced-apart bundles of reinforcing fibers are selectively cut to form multiple individual reinforcing fibers of desired length. As the first adhesive layer moves in the machine direction, the cut reinforcing fibers are distributed and arranged in a desired pattern on the first adhesive layer. The distribution and arrangement of the reinforcing fibers results in the formation of a patterned reinforcing fiber layer on the first adhesive layer. Preferably, the reinforcing fiber layer is initially spaced apart from the ends of the yarn stitches before curing.

[0013] After the first adhesive layer and the reinforcing fiber layer are formed, a second adhesive layer is formed on the reinforcing fiber layer as it moves along the machine direction. A sandwich-like base fabric is formed, comprising the reinforcing fiber layer sandwiched between the first and second adhesive layers. Before the second adhesive is formed as a layer on the reinforcing fibers, it is adjusted to form a plurality of voids within the second adhesive.

[0014] The sandwich base fabric can be dried, conditioned, or cured in an oven. The drying, conditioning, or curing provided by the oven does not eliminate multiple voids in the first and second adhesive layers, and the drying of the sandwich base fabric helps to provide adhesive rigidity.

[0015] After passing through the oven, the embossing machine applies pressure to the sandwich-shaped base fabric in a controlled manner. The sandwich-shaped base fabric is compressed by the embossing machine, and the ends of the yarn stitches are flattened. The compression provided by the embossing machine causes the first and second adhesive layers to collapse. The collapse of the adhesive layers eliminates the volume occupied by the voids in the first and second adhesive layers, resulting in a thinner and relatively stronger structure. The reinforcing fiber layer is also simultaneously moved by the embossing machine to engage and attach with the flat ends of the yarn stitches, and to a final position closer to the main base fabric substrate.

[0016] The compression provided by the embossing machine compresses both sides of the reinforcing fiber layer, causing the first and second adhesive layers to encapsulate the reinforcing fiber layer, and the compression fuses the adhesive layer and the reinforcing fiber layer together. The first and second adhesive layers bond with each other and sandwich the reinforcing fiber layer between them. Furthermore, the compression brings the reinforcing fiber layer closer to the main backing fabric substrate for stability and stiffness.

[0017] These and other features and advantages of the invention will be better understood by referring to the following description and the appended claims. The accompanying drawings, which form part of this specification, illustrate various embodiments of the invention and, together with the written description, serve to explain the principles of the methods and products of the invention.

[0018] Brief description of the accompanying drawings

[0019] The specification provides a complete and feasible disclosure of the method and the resulting product, including its best mode, to those skilled in the art, and includes reference to the accompanying drawings, in which:

[0020] Figure 1 A schematic diagram of an apparatus setup for attaching fibers and adhesive-reinforcing base fabric to a tufted textile substrate.

[0021] Figure 2 A top-view diagram is provided to enhance fiber distribution.

[0022] Figure 3 A schematic diagram showing the distribution of reinforcing fibers.

[0023] Figure 4 This is an enlarged schematic diagram illustrating the compression of the adhesive layer and the reinforcing fiber layer.

[0024] Detailed description

[0025] Schemes of the methods and resulting products are now provided for reference, one or more of which are illustrated in the accompanying drawings. Each embodiment is intended to explain the manner of the invention and is not intended to limit the invention. It will be apparent to those skilled in the art that various modifications and variations can be made to the invention without departing from the scope or spirit of the invention. Therefore, the invention is intended to cover such modifications and variations that fall within the scope of the appended claims and their equivalents.

[0026] Figure 1 This is a schematic diagram of an arrangement according to the invention for applying adhesive and reinforcing fibers to a tufted textile substrate to form a reinforced base fabric system. The floor covering includes a tufted textile substrate 10 made of yarns tufted through a main base fabric substrate 22. It is known that the main base fabric substrate 22 has a front side and a back side opposite to the front side. The yarns form stitches 12 on the back side of the main base fabric substrate 22, and there are gaps between each yarn.

[0027] The manufacturing process disclosed herein begins by conditioning a first adhesive 14 to form a plurality of voids 16 within the adhesive 14. In a preferred embodiment, the adhesive 14 is a thermoplastic adhesive. Preferably, the adhesive 14 has stretchable and reformable properties when exposed to heat or compression. It is also preferred that the adhesive 14 is water-based to facilitate the manufacturing process, which will be described further. For example, air can be injected into the water-based adhesive 14 to create voids in the form of bubbles, thereby allowing the adhesive 14 to be compressed as required during the manufacturing process.

[0028] After adjusting the adhesive 14 to create the gap 16, the adhesive 14 moves along the machine direction to the first applicator 18. The applicator 18 applies pressure in a controlled manner to force the adhesive 14 toward the back side of the main backing fabric substrate 22. The adhesive 14 is forced into the stitches 12 and also into the space between the stitches 12. The movement of the adhesive 14 is further controlled by a vacuum 20 applied to the front side of the main backing fabric substrate 22. The applicator 18 and the vacuum 20 form a layer of the first adhesive 14 with the desired thickness, and this layer of adhesive 14 is movable along the machine direction.

[0029] like Figure 1 As shown, one or more bundles 24 of reinforcing fibers 28 are positioned relative to the moving first adhesive layer 14. A cutting mechanism 26 cuts the fiber bundles (multiple bundles) 24 into multiple individual reinforcing fibers 28. Each reinforcing fiber 28 is cut to the desired length. The cut reinforcing fibers 14 are distributed and arranged as desired. Figure 2 and 3 The pattern is shown schematically.

[0030] The dispensing and setting device 30 for reinforcing fiber 28 is schematically shown in Figure 1-3 In the middle. After being cut from bundle 24, the cut reinforcing fibers 28 are positioned on the moving adhesive layer 14 in a generally linear or machine orientation. Figure 2 This illustrates the generally linear or machine-oriented configuration of the reinforcing fibers 28 on the adhesive 14 after the fibers 28 have been cut from the bundle 24. Figure 2 and 3 The image shows the cutting and linearly positioned reinforcing fibers 28 from two spaced-apart fiber bundles 24.

[0031] After the reinforcing fibers 28 are initially positioned in a linear or generally machine-oriented configuration, the dispensing and setting device 30 moves in a horizontal direction generally perpendicular to the machine direction. For example... Figure 2 and Figure 3 As shown, the device 30 includes fingers 42. The device 30 moves vertically toward and away from the needle 12, and also reciprocates or oscillates horizontally in a direction perpendicular to the machine direction. The amount and type of distribution and placement of the reinforcing fibers 28 can be controlled by selectively adjusting the speed of movement of the reinforcing fibers 28 in the machine direction and the duration of the reciprocating motion or oscillation provided by the device 30.

[0032] The movement of device 30 causes fingers 42 to distribute reinforcing fibers 28 in the horizontal direction and arrange the reinforcing fibers 28 into a desired pattern. For example, as Figure 2 As shown, the desired pattern may include the positioning of the reinforcing fiber 28 in the machine direction and the positioning of the reinforcing fiber at various other angles relative to the machine direction. Furthermore, as... Figure 2 As shown, the reinforcing fibers 28 have sufficient length to allow the fibers 28 to bend or curl, such that the bent or curled fibers 28 extend in more than one direction. The patterned reinforcing layer, comprising the multidirectional and overlapping arrangement of the reinforcing fibers 28, is preferably initially formed at a location spaced apart from the ends of the stitches 12.

[0033] After forming the first adhesive layer 14 and the patterned reinforcing fiber layer 28, a second adhesive layer 32 is formed. The second adhesive 32 is adjusted to allow the formation of a plurality of voids 34 within it. Preferably, the second adhesive 32 is a thermoplastic adhesive that is ductile and reformable when exposed to heat or compression. Also preferably, the second adhesive 32 is a water-based adhesive. Similar to the first adhesive 14, air can be injected into the water-based adhesive 32 to create voids 34 in the form of bubbles, thereby allowing the adhesive 32 to be compressed as required during the manufacturing process.

[0034] like Figure 1As shown, the adjusted second adhesive 32 is formed as a layer by the second applicator 36. The adhesive 32 layer is formed and placed on the patterned reinforcing fiber 28 layer. The reinforcing fiber 28 layer, the first adhesive 14 layer, and the second adhesive 32 layer form a sandwich-shaped reinforcing base fabric. That is, the patterned reinforcing fiber 28 is sandwiched between the adhesive 14 layer and the adhesive 32 layer to form a sandwich-shaped reinforcing base fabric.

[0035] A sandwich-shaped reinforcing base fabric, consisting of a sandwich of reinforcing fibers 28 and adhesives 14 and 32, can be dried, conditioned, or cured in an oven 38. It is anticipated that the drying, conditioning, or curing provided by the oven 38 will not eliminate voids 16 and 34 in the first and second adhesives 14 and 32. The drying process provided by the oven 38 removes water and provides the desired adhesive rigidity. Since the preferred adhesive is a water-based thermoplastic containing, for example, pores, it is desirable to remove water from the adhesive and dry it to provide it with some rigidity while allowing the adhesive to retain its ductility and reformability.

[0036] like Figure 1 and 4 As shown, after passing through the oven 38, a third applicator 40 applies pressure in a controlled manner to the sandwich-shaped reinforcing base fabric consisting of layers 28 of reinforcing fibers and layers 14 and 32 of adhesives. The third applicator 40 may be an embossing machine that compresses the layers 28 of reinforcing fibers and layers 14 and 32 of adhesives and flattens the ends of the stitches 12.

[0037] The compression provided by the third applicator 40 causes the relatively rigid, dry adhesive layers 14 and 32 to collapse. The compression and collapse action applied to the adhesive layers reduces the volume occupied by voids 16 and 34 in the first and second adhesive layers 14 and 32. This results in a thinner and relatively robust structure consisting of the compressed and collapsed adhesive layers 14 and 32 sandwiched between reinforcing fiber layers 28. The resulting reinforcing fiber layers 28 and adhesive layers 14 and 32 are also simultaneously moved by the third applicator 40 to engage and attach to the flat end surface of the yarn needle 12. Further as... Figure 1 and 4 As shown, the reinforcing fiber 22 layer moves to a final position close to or joined with the main backing fabric substrate 22.

[0038] Compression from the third applicator 40 compresses both sides of the reinforcing fiber 28 layer, causing the first adhesive layer 14 and the second adhesive layer 32 to encapsulate and trap the reinforcing fiber 28 layer. Furthermore, the compression and collapse of adhesive layers 14 and 32 bond them together. Additionally, by arranging the reinforcing fiber 28 into the desired pattern and moving the reinforcing fiber 22 layer to its final position, which, upon curing, is close to or engages with the main backing fabric substrate 22, additional stability and stiffness are provided to the tufted textile substrate 10.

[0039] Without departing from the spirit and essential attributes of the invention, the invention may be embodied in other forms. Therefore, reference should be made to the appended claims, and not only to the foregoing description, as indication of the scope of the invention.

Claims

1. A method for manufacturing a floor covering, the method comprising the following steps: A floor covering is manufactured from a set of components, the components including: a tufted textile substrate having a main backing substrate extending in a first direction; and a plurality of yarns having tufts passing through the main backing substrate, the main backing substrate having a front side and a back side opposite to the front side, a portion of each yarn forming: a stitched portion having one end located on the back side of the main backing substrate; and a space existing between the stitched portions; The first adhesive is adjusted to form a plurality of voids within the first adhesive, pressure is applied to the first adhesive to force the first adhesive to move toward the back side of the main backing fabric substrate to form a first adhesive layer, and the first adhesive layer is moved in a first direction; Cut at least one bundle of reinforcing fibers and form multiple separate reinforcing fibers on the first adhesive along a first direction; A patterned reinforcing fiber layer is formed on the first adhesive layer. The patterned reinforcing fiber layer is formed by multiple separate reinforcing fibers. The patterned reinforcing fiber layer is formed at an initial position spaced apart from the main base fabric substrate. The patterned reinforcing fiber layer is moved together with the first adhesive layer along a first direction. The second adhesive is adjusted to form a plurality of voids within the second adhesive, forming a second adhesive layer, and the second adhesive layer is moved in a first direction; The patterned reinforcing fiber layer is sandwiched between the first and second adhesive layers, and the patterned reinforcing fiber layer and the first and second adhesive layers are moved in a first direction; and The first adhesive layer and the second adhesive layer are compressed, while the voids in the first adhesive layer and the second adhesive layer are collapsed, and the patterned reinforcing fiber layer is moved to a final position that is closer to the main substrate than the initial position of the patterned reinforcing fiber layer.

2. The method for manufacturing the floor covering as described in claim 1, wherein, The formation of the patterned reinforcing fiber layer further includes: distributing and setting the multiple individual reinforcing fibers, and forming a multi-directional overlapping patterned reinforcing fiber layer.

3. The method of manufacturing a floor covering as claimed in claim 1, further comprising drying the first adhesive layer and the second adhesive layer before compressing the first adhesive layer and the second adhesive layer to provide rigidity to the first adhesive layer and the second adhesive layer without eliminating voids within the first and second adhesive layers.

4. A method for manufacturing a floor covering, the method comprising the following steps: A floor covering is manufactured from a set of components, the components including: a tufted textile substrate having a main backing fabric substrate that moves in a first direction; and a plurality of yarns, the tufts of which pass through the main backing fabric substrate, the main backing fabric substrate having a front side and a back side opposite to the front side, a portion of each yarn being formed; a stitched portion having one end located on the back side of the main backing fabric substrate; and a space existing between the stitched portions; The first adhesive is adjusted to form a plurality of voids within the first adhesive, forming a first adhesive layer, and the first adhesive layer is moved in a first direction; A reinforcing fiber layer is formed along a first direction at a first position spaced apart from the main base fabric substrate, and the reinforcing fiber layer is moved in the first direction; The second adhesive is adjusted to form a plurality of voids within the second adhesive, forming a second adhesive layer, and the second adhesive layer is moved in a first direction; The reinforcing fiber layer is placed between the first and second adhesive layers; and The first adhesive layer and the second adhesive layer are compressed to simultaneously collapse the voids in the first adhesive and the second adhesive, and the reinforcing fiber layer is moved to a second position, which is closer to the main backing fabric substrate than the first position; the ends of the stitches are flattened to form a bonding surface for attaching the reinforcing fiber layer to the stitches.

5. The method of manufacturing the floor covering as claimed in claim 4, further comprising encapsulating the reinforcing fibers with the first adhesive layer and the second adhesive layer, and bonding the first adhesive layer and the second adhesive layer together.

6. The method of manufacturing a floor covering as claimed in claim 4, further comprising distributing and setting the reinforcing fibers, and forming a multidirectional overlapping patterned layer of the reinforcing fibers.

7. The method of manufacturing a floor covering as claimed in claim 4, further comprising drying the first adhesive layer and the second adhesive layer before compressing the first adhesive layer and the second adhesive layer to provide rigidity to the first adhesive layer and the second adhesive layer without eliminating voids in the first and second adhesives.

8. A method for manufacturing floor coverings, the method comprising the following steps: A floor covering is manufactured from a set of components, the components including: a tufted textile substrate having a main backing fabric substrate that moves in a first direction; and a plurality of yarns, the tufts of which pass through the main backing fabric substrate, the main backing fabric substrate having a front side and a back side opposite to the front side, a portion of each yarn forming: a stitched portion having one end located on the back side of the main backing fabric substrate; and a space existing between the stitched portions; Multiple voids are formed in the first adhesive layer to form a first adhesive layer that bonds with the main base fabric substrate, and the first adhesive layer is moved in the first direction; A reinforcing fiber layer is formed on one side of the first adhesive layer, the reinforcing fiber layer is positioned at an initial position spaced apart from the main base fabric substrate and from the end of the stitch, and the reinforcing fiber layer is moved in the first direction; Multiple voids are formed in the second adhesive layer, and the second adhesive layer is positioned to bond to one side of the reinforcing fiber layer such that the reinforcing fiber layer is located between the first adhesive layer and the second adhesive layer, and the second adhesive layer is moved in a first direction; The first and second adhesive layers are cured and rigidified without eliminating voids in the first and second adhesives; and After the first and second adhesive layers are cured, the first and second adhesive layers are compressed, while the voids in the first and second adhesives are collapsed, and the reinforcing fiber layer is moved to its final position, the reinforcing fiber layer is joined and attached to the end of the pin, and the space between the reinforcing fiber layer and the main base fabric substrate is reduced.

9. The method of manufacturing a floor covering as claimed in claim 8, further comprising flattening the ends of the pins to form a bonding and attachment surface for attaching the reinforcing fiber layer to the pins.

10. The method of manufacturing a floor covering as claimed in claim 8, further comprising distributing and setting the reinforcing fibers, and forming a multidirectional overlapping pattern of the reinforcing fibers.

11. The method of manufacturing a floor covering as claimed in claim 8, further comprising encapsulating the reinforcing fibers with a first adhesive layer and a second adhesive layer, and bonding the first adhesive layer and the second adhesive layer together.

Images