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NZ761516B2 - Low weight modular carpet components and methods of making the same - Google Patents
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NZ761516B2 - Low weight modular carpet components and methods of making the same - Google Patents

Low weight modular carpet components and methods of making the same

Info

Publication number
NZ761516B2
NZ761516B2 NZ761516A NZ76151618A NZ761516B2 NZ 761516 B2 NZ761516 B2 NZ 761516B2 NZ 761516 A NZ761516 A NZ 761516A NZ 76151618 A NZ76151618 A NZ 76151618A NZ 761516 B2 NZ761516 B2 NZ 761516B2
Authority
NZ
New Zealand
Prior art keywords
carpet tile
layer
facecloth
extruded polymer
reinforcing scrim
Prior art date
Application number
NZ761516A
Other versions
NZ761516A (en
Inventor
Michael E Bell
Michael Christopher Gallman
Original Assignee
Aladdin Manufacturing Corporation
Filing date
Publication date
Priority claimed from US15/703,195 external-priority patent/US11260621B2/en
Application filed by Aladdin Manufacturing Corporation filed Critical Aladdin Manufacturing Corporation
Priority to NZ802643A priority Critical patent/NZ802643A/en
Publication of NZ761516A publication Critical patent/NZ761516A/en
Publication of NZ761516B2 publication Critical patent/NZ761516B2/en

Links

Classifications

    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47G—HOUSEHOLD OR TABLE EQUIPMENT
    • A47G27/00—Floor fabrics; Fastenings therefor
    • A47G27/02—Carpets; Stair runners; Bedside rugs; Foot mats
    • A47G27/0293—Mat modules for interlocking engagement
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0276—Polyester fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/101—Glass fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2471/00—Floor coverings
    • B32B2471/02—Carpets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/10—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/15—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer being manufactured and immediately laminated before reaching its stable state, e.g. in which a layer is extruded and laminated while in semi-molten state
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/028—Net structure, e.g. spaced apart filaments bonded at the crossing points
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2201/00—Chemical constitution of the fibres, threads or yarns
    • D06N2201/08—Inorganic fibres
    • D06N2201/082—Glass fibres
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2201/00—Chemical constitution of the fibres, threads or yarns
    • D06N2201/10—Conjugate fibres, e.g. core-sheath, side-by-side
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2203/00—Macromolecular materials of the coating layers
    • D06N2203/04—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D06N2203/042—Polyolefin (co)polymers
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
    • D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
    • D06N7/0071—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing
    • D06N7/0076—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing the back coating or pre-coat being a thermoplastic material applied by, e.g. extrusion coating, powder coating or laminating a thermoplastic film
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
    • D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
    • D06N7/0071—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing
    • D06N7/0081—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing with at least one extra fibrous layer at the backing, e.g. stabilizing fibrous layer, fibrous secondary backing

Abstract

low-weight carpet tile and process for making the same, wherein the carpet tile (100) comprises a facecloth (111) having a plurality of face yarns (105) tufted through a primary backing (110), an extruded polymer secondary backing layer (120), and a reinforcing scrim layer (130) partially embedded within the extruded polymer secondary backing layer. The top surface and bottom surface of the carpet tile are defined by the facecloth and the reinforcing scrim layer, respectively. A polymer-based resin is extruded onto the facecloth to form an at least substantially uniform secondary backing layer, and the reinforcing scrim layer is laid onto the extruded polymer secondary backing layer while the extruded polymer secondary backing layer remains above a softening temperature for the resin. The entire multi-layer web is then passed through a nip to embed the reinforcing scrim layer into the extruded polymer secondary layer, and the entire web is chilled.

Claims (22)

CLAIMS :
1. A carpet tile comprising: a facecloth comprising a primary backing and a plurality of face yarns extending through the primary backing, wherein the facecloth defines an upper 5 surface of the carpet tile; an extruded polymer secondary backing layer having a top surface bonded to the facecloth and an opposite bottom surface, wherein the bottom surface of the extruded polymer secondary backing layer is partially exposed at an outermost bottom surface of the carpet tile; and 10 a reinforcing scrim layer bonded to the bottom surface of the extruded polymer secondary backing, wherein the reinforcing scrim layer defines at least a portion of the outermost bottom surface of the carpet tile.
2. The carpet tile according to claim 1, wherein the reinforcing scrim layer comprises a plurality of fibers and wherein the plurality of fibers comprise at least 15 one of: glass fibers or polymer fibers.
3. The carpet tile according to claim 2, wherein the plurality of fibers comprise polymer fibers comprising sheathed polyester core fibers.
4. The carpet tile according to claim 2, wherein the plurality of fibers comprise glass fibers having a coating. 20
5. The carpet tile according to claim 4, wherein the coating comprises polyethylene.
6. The carpet tile according to any one of the preceding claims, wherein the reinforcing scrim layer comprises a nonwoven fibrous material.
7. The carpet tile according to any one of the preceding claims, wherein the 25 reinforcing scrim layer comprises a plurality of polymer fibers and a plurality of glass fibers.
8. The carpet tile according to any one of the preceding claims, wherein the extruded polymer secondary backing comprises a polyolefin.
9. The carpet tile according to claim 8, wherein the extruded polymer secondary backing comprises between 10 to 40 wt% polyolefin. 5
10. The carpet tile according to claim 8 or 9, wherein the extruded polymer secondary backing comprises between 20 to 80 wt% of a filler material.
11. The carpet tile according to any one of the preceding claims, wherein the weight of the carpet tile is between 1.356 to 2.373kg/m (between 40 to 70 ounces per square yard). 10
12. The carpet tile according to claim 11, wherein the weight of the carpet tile is between 1.695 to 2.034 kg/m (between 50 to 60 ounces per square yard).
13. The carpet tile according to any one of the preceding claims, wherein the facecloth further comprises a primary backing pre-coat layer between the primary backing layer and the extruded polymer secondary backing layer. 15
14. A method of manufacturing a carpet tile, the method comprising: providing a facecloth, wherein the facecloth comprises a primary backing having a plurality of face yarns extending through a facecloth; forming a multi-layer construction comprising the facecloth and a backing construction secured on a first side of the facecloth by: 20 extruding a polymer sheet onto the first side of the facecloth such that a top surface of the polymer sheet is bonded to the facecloth; pressing a fibrous reinforcing scrim layer partially into a bottom surface of the extruded polymer sheet to bond the fibrous reinforcing scrim layer to the bottom surface of the extruded polymer sheet; and 25 wherein the bottom surface of the extruded polymer sheet is partially exposed at an outermost bottom surface of the multi-layer construction, and the reinforcing scrim layer is partially exposed at the outermost bottom surface of the multi-layer construction.
15. The method according to claim 14, wherein pressing the fibrous reinforcing scrim layer partially into the extruded polymer sheet comprises compressing the multi-layer construction between nip rollers.
16. The method according to any one of the claims 14 to 15, further 5 comprising chilling the multi-layer construction.
17. The method according to any one of the claims 14 to 16, further comprising steps for cutting the multi-layer construction into a plurality of carpet tiles.
18. The method according to any one of the claims 14 to 17, wherein 10 extruding a polymer sheet comprises extruding a polyolefin-based resin, wherein the polyolefin-based resin comprises between 10 to 40 wt% polyolefin and between 20 to 80 wt% of a filler material.
19. The method according to any one of the claims 14 to 18, wherein pressing the fibrous reinforcing scrim layer partially into the extruded polymer sheet 15 comprises pressing a nonwoven fiber mat partially into the extruded polymer sheet.
20. The method according to any one of the claims 14 to19, wherein the fibrous reinforcing scrim layer comprises at least one of: fiberglass fibers or polymer fibers. 20
21. The method according to any one of the claims 14 to 20, wherein said steps for extruding a polymer sheet onto the first side of the facecloth and pressing a fibrous reinforcing scrim layer partially into the extruded polymer sheet collectively form a backing construction having a weight between 0.678 to 1.017 kg/m (between 20 to 30 ounces per square yard). 25
22. The method according to claim 21, wherein providing a facecloth comprises providing a primary backing web having a weight between 0.610 to 1.017 kg/m (between 18 to 30 ounces per square yard); and wherein the multi-layer construction has a weight between 1.288 to 2.034 kg/m (between 38 to 60 ounces per square yard).
NZ761516A 2017-09-13 2018-09-12 Low weight modular carpet components and methods of making the same NZ761516B2 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
NZ802643A NZ802643A (en) 2017-09-13 2018-09-12 Low weight modular carpet components and methods of making the same

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US15/703,195 US11260621B2 (en) 2017-09-13 2017-09-13 Low weight modular carpet components and methods of making the same
PCT/US2018/050577 WO2019055461A1 (en) 2017-09-13 2018-09-12 Low weight modular carpet components and methods of making the same

Publications (2)

Publication Number Publication Date
NZ761516A NZ761516A (en) 2025-10-31
NZ761516B2 true NZ761516B2 (en) 2026-02-03

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