U.S. patent application number 11/612601 was filed with the patent office on 2007-07-05 for flooring system and methods.
Invention is credited to Kenneth B. Higgins, N. David JR. Sellman, William Tippett.
Application Number | 20070154672 11/612601 |
Document ID | / |
Family ID | 31186953 |
Filed Date | 2007-07-05 |
United States Patent
Application |
20070154672 |
Kind Code |
A1 |
Higgins; Kenneth B. ; et
al. |
July 5, 2007 |
FLOORING SYSTEM AND METHODS
Abstract
A flooring system for use in a residential environment. The
flooring system includes a subfloor adapted to support the mass of
a user and modular surface covering elements for disposition in
edge to edge covering arrangement across at least a portion of the
subfloor. The modular surface covering elements include a pile
fabric face with an arrangement of yarns projecting outwardly
defining a pile layer for contact by a user. At least one layer of
cushioning material is disposed in contacting relation at a
position below the pile fabric face.
Inventors: |
Higgins; Kenneth B.;
(LaGrange, GA) ; Sellman; N. David JR.; (LaGrange,
GA) ; Tippett; William; (Lancashire, GB) |
Correspondence
Address: |
Legal Department (M-495)
P.O. Box 1926
Spartanburg
SC
29304
US
|
Family ID: |
31186953 |
Appl. No.: |
11/612601 |
Filed: |
December 19, 2006 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
10209050 |
Jul 31, 2002 |
7182989 |
|
|
11612601 |
Dec 19, 2006 |
|
|
|
10198238 |
Jul 18, 2002 |
|
|
|
10209050 |
Jul 31, 2002 |
|
|
|
10154187 |
May 23, 2002 |
|
|
|
10209050 |
Jul 31, 2002 |
|
|
|
10118059 |
Apr 8, 2002 |
|
|
|
10209050 |
Jul 31, 2002 |
|
|
|
09993158 |
Nov 16, 2001 |
|
|
|
10209050 |
Jul 31, 2002 |
|
|
|
09960114 |
Sep 21, 2001 |
|
|
|
10209050 |
Jul 31, 2002 |
|
|
|
09910085 |
Jul 20, 2001 |
|
|
|
10209050 |
Jul 31, 2002 |
|
|
|
Current U.S.
Class: |
428/51 ; 428/82;
428/88; 428/95 |
Current CPC
Class: |
Y10T 428/23929 20150401;
Y10T 428/16 20150115; Y10T 428/23907 20150401; D06N 2209/0807
20130101; D06N 2209/1671 20130101; B32B 5/18 20130101; B32B 5/24
20130101; B32B 2471/02 20130101; Y10T 428/23979 20150401; E04F
2201/096 20130101; B32B 3/02 20130101; B32B 25/12 20130101; D06N
7/0078 20130101; E04F 2201/091 20130101; D06N 2203/042 20130101;
Y10T 428/168 20150115; D06N 7/0073 20130101; D06N 2203/065
20130101; B32B 5/245 20130101; B32B 2262/0253 20130101; B32B 5/22
20130101; Y10T 428/164 20150115; A47G 27/0475 20130101; B32B 25/10
20130101; D06N 7/0076 20130101; B32B 5/26 20130101; D06N 7/0065
20130101; D06N 7/0084 20130101; Y10T 428/23957 20150401; Y10T
428/163 20150115; B32B 27/12 20130101; A47G 27/0293 20130101 |
Class at
Publication: |
428/051 ;
428/082; 428/088; 428/095 |
International
Class: |
B32B 3/14 20060101
B32B003/14; B32B 33/00 20060101 B32B033/00 |
Claims
1. A flooring system for use in a residential environment
comprising: a plurality of modular surface covering elements
including a plurality of edges, wherein the modular surface
covering elements are configured for disposition in edge to edge
covering arrangement across at least a portion of a subfloor, the
modular surface covering elements comprising a pile fabric face
including a primary base and a plurality of yarns projecting
outwardly from the primary base defining a pile layer for contact
by a user, the modular surface covering elements further comprising
at least one layer of cushioning material secured in substantially
fixed positional relation relative to the pile fabric face at a
position below the pile fabric face and wherein the pile layer has
a standard pile density in the range of about 500 to about 4,200
ounces per cubic yard and wherein the plurality of yarns projecting
outwardly from the primary base have an average extended length
above the primary base in the range of about 0.25 to about 1 inch,
wherein each of the modular surface covering elements in the
flooring system are of substantially identical geometry and have a
first edge including two outwardly projecting chevrons, a second
edge in opposing relation to the first edge including two inwardly
projecting chevrons in substantial alignment with the outwardly
projecting chevrons on the first edge, and two substantially
straight lateral edges extending between the first edge and the
second edge such that the inwardly projecting chevrons of any one
of the modular surface covering elements in the flooring system are
mateable in interlocking relation in one configuration of the
modular surface covering elements with both of the outwardly
projecting chevrons of an abutting modular surface covering element
in the flooring system and in another configuration of the modular
surface covering elements with one of the outwardly projecting
chevrons of an abutting modular surface covering element in the
flooring system.
2. The invention as recited in claim 1, wherein at least one of
said modular surface covering elements has a friction enhancing
coating on the bottom thereof.
3. The invention as recited in claim 1, wherein said layer of
cushioning material includes at least one layer of rebond foam.
4. The invention as recited in claim 1, wherein said layer of
cushioning material includes at least one layer of virgin, filled,
polyurethane foam.
5. A flooring system for use in a residential environment
comprising: a plurality of modular surface covering elements
including a plurality of edges, wherein the modular surface
covering elements are configured for disposition in edge to edge
covering arrangement across at least a portion of a subfloor, the
modular surface covering elements comprising a pile fabric face
including a primary base and a plurality of yarns projecting
outwardly from the primary base defining a pile layer for contact
by a user, the modular surface covering elements further comprising
at least one layer of cushioning material secured in substantially
fixed positional relation relative to the pile fabric face at a
position below the pile fabric face and wherein the pile layer has
a standard pile density in the range of about 500 to about 4,200
ounces per cubic yard and wherein the plurality of yarns projecting
outwardly from the primary base have an average extended length
above the primary base in the range of about 0.25 to about 1 inch,
wherein each of the modular surface covering elements in the
flooring system are of substantially identical geometry and have a
first edge having at least three outwardly projecting chevrons, a
second edge in opposing relation to the first edge including at
least three inwardly projecting chevrons each in substantial
alignment with one of the outwardly projecting chevrons, and two
substantially straight lateral edges extending between the first
edge and the second edge such that the inwardly projecting chevrons
of any one of the modular surface covering elements in the flooring
system are mateable in interlocking relation in one configuration
of the modular surface covering elements with all three of the
outwardly projecting chevrons of an abutting modular surface
covering element in the flooring system, and in another
configuration of the modular surface covering elements with two of
the outwardly projecting chevrons of one abutting modular surface
covering element and with one of the outwardly projecting chevrons
of a second abutting modular surface covering element in the
flooring system.
6. The invention as recited in claim 5, wherein at least one of
said modular surface covering elements has a friction enhancing
coating on the bottom thereof.
7. The invention as recited in claim 5, wherein said layer of
cushioning material includes at least one layer of rebond foam.
8. The invention as recited in claim 5, wherein said layer of
cushioning material includes at least one layer of virgin, filled,
polyurethane foam.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to flooring systems and more
particularly to flooring systems incorporating a multiplicity of
replaceable modular surface covering elements adapted for
installation in a coordinated arrangement across a supporting
subfloor. Constructions of modular surface coverings and methods of
formation and installation are also provided.
BACKGROUND OF THE INVENTION
[0002] Cushion back carpet products or carpet tiles are described
for example in U.S. Pat. Nos. 4,522,857 and 6,203,881 each hereby
incorporated by reference herein.
[0003] The evolution of flooring in the commercial and residential
markets has progressed in two distinct directions based
substantially on the requirements of the end user. One aspect of
the evolution of commercial floor coverings has been directed to
modular floor coverings. The commercial market is exemplified by
high traffic, both foot traffic and rolling equipment, and minimal
demand for plush, high, pile. A particular problem with commercial
applications is the formation of traffic lanes which cause a carpet
to show wear in certain lanes of traffic with minimal wear in other
areas. To avoid this visually distracting phenomenon, carpet
designed for commercial applications has evolved into a material
with low mat, minimal or no cushion, and the wide spread use of
carpet tiles which can be individually replaced when damaged.
[0004] An excellent commercial cushion backed carpet tile or
modular cushion back carpet product on the market today, for
example, sold under the trademark Comfort Plus.RTM. by Milliken
& Company of LaGrange, Ga. has a structure similar to, for
example FIGS. 3A or 3B of U.S. Pat. No. 6,203,881 (incorporated by
reference herein), and has a commercial primary carpet fabric with
a face weight of about 20 to 40 oz/yd.sup.2, a hot melt layer of
about 38 to 54 oz/yd.sup.2, a prime filled polyurethane foam
cushion of about 0.10 to 0.2 inches thick, a cushion weight of
about 28-34 oz/yd.sup.2, a cushion density of about 16-18 lbs. per
cubic foot, and an overall product height of about 0.4-0.8 inches.
This superior commercial cushion back carpet tile provides
excellent resilience and under foot comfort, exhibits performance
characteristics that rate it for 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 cushion backed carpet
tile is relatively expensive to produce due to the high quality and
quantity of materials utilized.
[0005] Floor coverings in the form of broadloom carpet for
residential use have demands which make a commercial carpet
undesirable and these divergent requirements have encouraged a
divergence in the technology for each market. The most critical
parameters for a viable residential carpet is related to the way a
carpet feels and looks. This need has only been met previously with
a secondary cushion, or pad, and a deep pile broadloom carpet.
Residential carpet is almost exclusively broadloom or wall-to-wall
carpet.
[0006] While broadloom carpet meets the aesthetic and comfort
requirements for residential use, there are deficiencies which have
not been met in the art. The installation of broadloom carpet
requires several steps including: a) installation of tack strips
around the border of the area to be carpeted; b) installation of a
cushion, or pad, in the area to be carpeted; c) overlaying the
broadloom carpet over the pad, without displacing the pad; d)
seaming the broadloom carpet pieces together, and e) stretching the
carpet and securing it in place by forcing the tack strip through
the carpet. This installation requires trained individuals and
involves the use of large, bulky, rolls of 12-14 foot wide
broadloom carpet and pad. Once a broadloom carpet is soiled or
damaged, the entire carpet must be removed for refurbishment or
replacement.
[0007] Although attempts have been made in the past at marketing
certain carpet tile products for use in the home, such as hardback
carpet tiles for the kitchen, such attempts have not been
successful. Hence, the residential carpet customer has been
substantially limited in the choice of home carpet products, for
example, to broadloom carpet installed by professional installers
over a separate broadloom carpet pad. Many consumers have foregone
carpet completely and have opted for linoleum, hardwood or
interlocking simulated wood panels, commonly referred to as Pergo,
since the choice in carpet does not provide a suitable
alternative.
[0008] Due to the conflicting demands of carpet for commercial
applications and carpet for residential applications advancements
in commercial products have not translated directly to suitable
products for residential use.
SUMMARY OF THE PRESENT INVENTION
[0009] Applicant has discovered that there has been a long standing
need and desire for a modular product or carpet tile which has the
look and feel of a residential deep pile carpet over pad. The
attributes that render a carpet suitable for use in residential are
in conflict with those properties which make for a commercial
carpet tile. For example, a residential carpet must be sufficiently
plush and padded to meet the needs of the residential consumer. Too
much cushioning in a commercial carpet tile is detrimental to the
performance. For example, when a weight is placed near the edge of
a carpet tile, the edge deflects thereby causing a ledge between
the carpet tile with the weight and the adjacent carpet tile. The
ledge creates many problems. Tiles can slide over one another,
often referred to as "snow-plowing". When the edges of adjacent
carpet tiles separate in a vertical direction the edge fibers can
enter the crevice created by the separation. As the edges attempt
to realign, the fibers are trapped in the crevice and appear to be
matted. This renders the seam highly visible. In severe cases the
separation can be a tripping hazard.
[0010] Further, Applicants are unaware of any modular carpeting
product which has fully satisfied the needs of adequate cushioning,
plush pile, and minimal edge displacement, and is durable with use
relevant to a residential installation.
[0011] According to one aspect of the present invention, a floor
covering system is provided including modular surface covering
elements including a pile face suitable for installation and use in
a residential application.
[0012] According to another aspect of the invention, a method is
provided for forming a residential modular carpet and carpet tile
having resilience, under foot comfort, the look and feel of
broadloom carpet, seamless appearance when installed, which is easy
to install, can be installed by the homeowner, and has performance
characteristics that rate it for residential or home use.
[0013] According to another aspect of the present invention, a
flooring system is provided including modular surface covering
elements of geometry to facilitate cooperative arrangement of
elements across a flooring surface so as to obscure the appearance
of seams between elements.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The accompanying drawings which are incorporated in and
which constitute a part of this specification illustrate an
exemplary embodiment of the present invention and together with the
detailed description set forth below serve to explain the
principles of the invention wherein:
[0015] FIGS. 1-12 are top view illustrations of geometries and
patterning arrangements for surface covering elements across a
supporting subfloor;
[0016] FIGS. 13A-13D are cut-away side view illustrations of
various multi-layered constructions for surface covering elements
for disposition across a subfloor;
[0017] FIGS. 14A-14B are schematic perspective view illustrations
of a production process for multi-layered constructions for surface
covering elements for disposition across a subfloor;
[0018] FIGS. 15A-23 are cut-away side view illustrations of various
multi-layered constructions for surface covering elements for
disposition across a subfloor;
[0019] FIGS. 24A-24B are schematic side view illustrations of a
cutting operation for cutting multi-layered constructions from the
back;
[0020] FIG. 25 is a side view illustration of a back to back
packaging arrangement for surface covering elements having a pile
face;
[0021] FIG. 26 is a side view illustration of a back to face
packaging arrangement for surface covering elements having a pile
face such as may occur in a roll; and
[0022] FIG. 27 is a graph showing average gap length between
surface covering elements of various constructions.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0023] Exemplary embodiments of the present invention will now be
described by reference to the accompanying drawings, in which, to
the extent possible, like reference numerals are used to designate
like components in the various views. In FIG. 1, an exemplary
flooring system is shown schematically in which a multiplicity of
modular surface covering elements 10 such as carpet tiles or the
like are arranged in edge to edge relation across a supporting
subfloor 11. As will be appreciated, the subfloor 11 may comprise
any surface suitable to provide support beneath the surface
covering elements 10. By way of example only, materials forming the
subfloor 11 may include raised access flooring, plywood, wood
particle board, hardwood, concrete, tile, ceramic tile, vinyl or
laminate, used carpeting or the like.
[0024] Regardless of the subfloor being covered, it is contemplated
that the surface covering elements will preferably provide an
aesthetically pleasing coordinated covering in which the juncture
between the individual surface covering elements is not
substantially discernible to an observer viewing the final
installation. That is, individual seams between the surface
covering elements are preferably hidden. Moreover, it is desired
that the individual surface covering elements should be readily
removeable after initial placement across the subfloor so as to
permit repositioning and/or subsequent replacement as desired. In
addition, the surface covering elements preferably should have
sufficient internal dimensional stability such that once they are
placed across the subfloor they maintain their initial geometry and
relative position such that seams do not open up over time.
Finally, it is desired that the individual surface covering
elements should impart a degree of cushioning across the surface of
the subfloor being covered. Such cushioning may be particularly
desirable for installations in residential environments where
comfort may be at a premium.
[0025] It is believed that the ability to hide seams may be
enhanced by incorporating a three dimensional face covering of
defined character across the side of the surface covering elements
facing away from the subfloor. The geometry of the surface covering
elements and the arrangement of the surface covering elements
relative to one another across the subfloor may also influence the
ability to hide seams. By way of example only, FIGS. 2-12 provide
schematic representations of at least partial installations of
different shaped surface covering elements. In particular, FIG. 2
illustrates an arrangement of substantially square surface covering
elements 10 arranged in offset relation. It is believed that the
use of such offset placement may in some instances tend to break up
the perceived continuity of the seams between the surface covering
elements. As will be appreciated, the surface covering elements
need not be square. Thus, in FIG. 3, there is illustrated an
arrangement of substantially elongate surface covering elements 10A
of generally rectangular configuration. By way of example only, it
is contemplated that such an arrangement may be particularly useful
in the event that the surface covering elements are supplied in a
roll form or large sheets to be laid down across a subfloor.
[0026] Aside from straight sided quadrilateral geometries, it is
also contemplated that any number of other geometries including
multisided polygonal geometries may also be used. It is believed
that the abutting relation of angled edges may provide a dual
benefit of facilitating proper installation across the subfloor
while also tending to break up the perceived continuity of the
seams between the surface covering elements.
[0027] FIGS. 4 and 5 illustrate arrangements of one exemplary
geometry for a surface covering element 10B having a double chevron
on each of two opposing sides (preferably the upper and lower
edges) and with the remaining two opposing sides being straight and
parallel. As shown, such surface covering elements may be installed
in either substantially aligned or staggered relation across a
subfloor. The double chevrons on opposite sides of the tile are
preferably complements of one another (fit with an adjacent or
abutting tile) in that on one side the chevrons are external
chevrons which protrude outwardly in a generally convex orientation
while on the other side the chevrons are internal chevrons which
are recessed in a generally concave orientation.
[0028] While the surface covering elements may be of virtually any
size as may be desired, in order to reduce the number of elements
required to cover a subfloor surface it may be desirable to use
surface covering elements of relatively large dimensions. However,
these dimensions should be balanced with the need of a user to
physically place the surface covering elements across the subfloor
during installation. By way of example only, and not limitation,
according to one contemplated construction the surface covering
elements having a geometry as shown in FIGS. 4 and 5 have straight
lateral sides of about 17 inches, each chevron has a width at its
base of about 9 inches (one-half the tile width) and a depth
(measured normal to the apex) of about one inch. Hence, the
resultant surface covering element has nominal outer dimensions of
about 18''.times.18'' which is believed to be of a size which can
be handled manually. One can make a rectangular tile by either
lengthening the straight sides or by widening the chevrons or
adding additional chevrons. By way of example only, one
contemplated surface covering element having a substantially
rectangular nominal outer dimensions has straight sides of about 22
inches, each chevron has a width of about 111/2 inches, and a depth
of about 1 inch. Thus, the nominal outer dimensions are 23
inches.times.23 inches.
[0029] Of course, it is to be appreciated that any number of other
geometric configurations may also be used in formation of the
surface covering elements. By way of example only and not
limitation, FIG. 6 illustrates rectangular surface covering
elements 10C with a single chevron on two opposing sides or ends.
FIG. 7 shows rectangular surface covering elements 10D with
multiple (triple) chevrons on two opposing sides or ends. FIG. 8
shows surface covering elements 10E with a single chevron on four
sides thereof. Note that the opposing chevrons are preferably
respective external and internal chevrons. FIG. 9 shows an
arrangement of surface covering elements 10F having a single lobe
or curved element on four sides thereof. FIG. 10 illustrates a
plurality of triangular shaped surface covering elements 10G
arranged in an offset pattern. FIG. 11 illustrates a plurality of
diamond shaped surface covering elements 10H arranged in an offset
pattern. FIG. 12 illustrates a plurality of hexagonal surface
covering elements 10I.
[0030] As illustrated, according to a potentially preferred
practice, each of the modular surface covering elements is
preferably substantially identical in configuration to other
surface covering elements disposed across the subfloor. Such
uniformity of geometry is believed to substantially reduce the
complexity of installation which may be useful to users without
substantial experience in the installation of flooring systems.
[0031] As previously indicated, the ability to hide the seams
between the individual surface covering elements may be enhanced by
incorporating a substantially three dimensional face covering of
defined character across the side of the surface covering element
facing away from the subfloor. In particular, it has been found
that the disposition of a three dimensional pile construction
having tufts of adequate height and population density across the
surface covering element may be useful in obscuring the seams
between adjacent surface covering elements even if no pattern
coloration is utilized. As will be described further hereinafter,
such a three dimensional pile construction may also provide a
cushioning effect which may be desired by users in a residential
environment.
[0032] According to one contemplated practice, the surface covering
elements disposed across the subfloor are multi-layer composite
carpet tile structures including a plurality of yarns defining an
outer face projecting away from the subfloor. The yarns are tufted
or bonded in place relative to a dimensionally stable backing
structure. The yarns are present at a height and population density
to provide cushioning and seam hiding characteristics. The backing
structure distributes loads applied across the surface covering
element and provides dimensional stability to the structure
covering element such that shape is maintained over time. If
desired, the supporting backing structure may include one or more
layers of a cushioning material such as foam or the like to further
enhance comfort during use.
[0033] Referring to FIGS. 13A, 13B, 13C, 13D exemplary potentially
preferred constructions of multi-layer surface covering elements
for use in overlaying relation to a subfloor 111 are provided. As
illustrated, constructions 110A, 110B, 110C 110D as may be used in
surface covering elements of any of the previously described
geometries each incorporate a layered arrangement of a pile forming
primary pile fabric 112 in overlying relation to a load
distributing layer 157 which in turn is disposed in overlying
relation to a layer of cushioning material 178, such as virgin
foam, or rebonded foam or compressed particle foam which may
include an optional backing layer 170. If desired, the backing
layer 170 may also include a friction enhancing coating or chemical
treatment 180 (FIG. 13D) as will be described further
hereinafter.
[0034] The load distributing layer 157 may include a sheet of
reinforcement material 158 such as glass or the like in combination
with a tie coat material 160 such as a thermoplastic adhesive or
thermoset adhesive, preferably a hot melt adhesive or the like to
establish a bonding relationship between the primary pile fabric
112 and the cushioning material 178. It is also contemplated that
the load distributing layer may be substantially free of any
reinforcement material if desired. That is, the load distribution
layer 157 may be formed substantially entirely of one or more
layers of tie coat material 160.
[0035] It is contemplated that the primary pile fabric 112 may
incorporate either a tufted or a bonded configuration (with loop
and/or cut pile) as will be well known. It is also contemplated
that the primary pile fabric 112 may take on any number of other
pile forming constructions including by way of example only and not
limitation, textured fabrics having woven, knit, or non-woven
constructions.
[0036] According to a potentially preferred practice, the primary
pile fabric 112 includes a plurality of pile-forming yarns
projecting outwardly from one side of a primary base. If the
primary pile fabric 112 used in the present invention is a tufted
construction as illustrated in FIGS. 13A, 13B and 13C, the primary
base is preferably made up of a primary backing 122 and an adhesive
pre-coat 124 such as latex or the like. As will be appreciated, the
constructions illustrated in FIGS. 13A and 13B are identical except
that the pile forming yarns 121 of the embodiment shown in FIG. 13B
have undergone a tip shearing or loop cutting operation to yield a
cut pile construction. The construction illustrated in FIG. 13D is,
in turn, substantially identical to that of FIG. 13B but
incorporating pile yarns 121' of a high twist construction such as
a frieze construction or the like which imparts substantial kink to
the yarns. As will be described further hereinafter, such yarn
constructions may be particularly desirable in residential
applications where a deep cushioning feel is desired.
[0037] In the illustrated bonded surface construction 110C of the
present invention (FIG. 13C), the primary pile fabric 112
preferably includes 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 or thermoset
materials or polymers to permit melting adhesion with the cut pile
yarns 134 upon the application of heat, thereby enhancing yarn
stability.
[0038] Although certain embodiments may be preferred, it is to be
understood that the primary pile fabric 112 may have different
embodiments, and the component structure of the primary carpet
fabric 112 is not limited. Rather it is intended that any suitable
primary pile fabric having a pile forming portion and a primary
base or backing may be utilized as the primary pile fabric. By
"primary base" is meant any single layer or composite structure
including, inter alia, the commonly used layered composite of
primary backing 122 and latex pre-coat 124 typically used in tufted
carpet constructions and the adhesive layer 136 with reinforcement
substrate 138 typically used in bonded constructions. 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 can be heat tacked to the substrate 138 as
described in U.S. Pat. No. 5,443,881 (hereby incorporated by
reference herein) to permit simplified construction of a primary
carpet.
[0039] Alternative embodiments including those disclosed in U.S.
Pat. No. 4,576,665 to Machell (incorporated by reference) may
likewise be utilized.
[0040] In accordance with a potentially preferred practice, the
pile yarn 120, 121, 121' or 134 of constructions 110A, 110B, 110C
and 110D, respectively, is capable of being dyed or printed, such
as jet dyed, flood dyed, rotary printed, or the like, by, for
example, using a Millitron.RTM. jet dye machine marketed by
Milliken & Company of LaGrange, Ga. Also, it is preferred that
the complete construction 110A, 110B, 110C, 110D of FIGS. 13A-13D
are capable of being jet dyed, rotary printed, or the like. For
example, the exemplary construction used to form the surface
covering elements are preferably capable of withstanding the rigors
of a jet dye process including dyeing, steaming, washing, drying,
and the like. Consequently, the surface covering elements can
withstand heat and humidity changes, and the yarn can be dyed or
printed. For example, the yarn may be white, light colored, such as
off white or light beige, yarn dyed, solution dyed, or the
like.
[0041] In accordance with at least one embodiment, it is preferred
to add an anti-bacterial, anti-fungal or anti-microbial agent, such
as ALPHASAN.TM. marketed by Milliken & Company of Spartanburg,
S.C., to at least the latex pre-coat layer if not to the latex
pre-coat layer and/or to the face yarn, primary backing, tie-coat
layer, reinforcement material, foam or cushion, backing, and/or
friction enhancing coating or grip layer. ALPHASAN.TM. is a silver
based anti-microbial agent which can withstand heat during
processing.
[0042] The yarns 120, 121, 121' and 134 may be either spun or
filament yarns and are preferably formed from a polyamide polymer
such as nylon 6 staple, nylon 6 filament, nylon 6,6 staple, or
nylon 6,6 filament, available from commercial sources such as
DuPont in Wilmington, Del. and Solutia Fibers of St. Louis, Mo.
However, other suitable natural or synthetic yarns or blends 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,
polyethylene terephthalate (PET), and polybutylene terephthalate
(PBT), polyolefins, such as polyethylene and polypropylene staple
or filament, rayon, polyvinyl polymers such as polyacrylonitrile,
wool, and blends thereof. A variety of deniers, plies, twist
levels, air entanglement, and heatset characteristics can be used
to construct the yarn.
[0043] Although it may be preferred that the yarn (or fiber) be a
white or light color to facilitate injection dyeing or printing
thereof, it is to be understood that the yarn may be of any nature
and color such as solution dyed, naturally colored, and the like,
and be adapted for dye injection printing, screen printing,
transfer printing, graphics tufting, weaving, knitting, and/or the
like.
[0044] According to one embodiment, the weight of the yarn within
the primary pile fabric will be about 10 ounces per square yard to
about 75 ounces per square yard and will more preferably be about
20 ounces per square yard to about 60 ounces per square yard and
will most preferably be about 38-39 ounces per square yard.
[0045] In accordance with a potentially preferred construction
illustrated in FIG. 13D, the primary pile fabric has a face
construction such as a frieze cut pile, a saxony cut pile, a loop
pile, a Berber loop pile, or the like. A frieze cut pile
construction may be potentially preferred. Such constructions
provide bulk through the pile due to the fact that the terminal
ends of the individual pile yarns are kinked such that the extended
length of the yarns actually exceeds the pile height. This bulking
gives rise to enhanced compressibility in the thickness dimension
of the surface covering element. Such enhanced compressibility is
believed to correlate to a generally cushioned feel by a user.
[0046] Exemplary and potentially preferred construction features
for a pile fabric of tufted construction for use in a surface
covering element according to the present invention are provided in
the following table. TABLE-US-00001 Primary Pile Fabric
Construction Pile Parameter Range Preferred Yarn Denier 900-3000
1180 Yarn Ply 1-4 2 Yarn Twist 2-9 7.5 Yarn Stitch 6-12/inch
7.7/inch Rate Gauge 3/16- 5/64 1/8 Face Weight 10-75 oz/yd.sup.2 38
oz/yd.sup.2 Pile Height 0.3''-1.5'' 0.75'' Measured From Above
Primary Backing
[0047] As will be appreciated, the desired depth and population
density of pile forming yarns across a surface covering element may
differ depending upon the intended environment of use. In
particular, it is believed that a deeper less populous pile
construction may be desired if the surface covering elements are to
be used in covering relation to a floor in a residential
environment such as a user's home. Conversely, shorter pile which
is packed closer together may be desired if the surface covering
elements are to be used in a commercial environment such as an
office, a hospitality environment such as a hotel or an
institutional environment such as schools or hospitals.
[0048] By way of example only, one potentially preferred cut pile
primary pile fabric with a frieze twist formed according to the
parameters set forth in the above table for use in surface covering
elements for residential applications is characterized by a normal
resultant pile depth of about 0.418 inches above the primary
backing with a pile length above the primary backing (measured by
pulling the yarn to its full extended length) of about 0.6 inches.
The mass per unit area of yarn above the primary backing (or other
primary base) measured by shaving the yarn across the primary
backing and weighing the resultant product is about 29.08 ounces
per square yard. Based upon the measured normal depth of 0.418
inches, the standard pile density is about 2,504.5 ounces per cubic
yard.
[0049] The term "standard pile density" is to be understood to be
the ratio of the mass of yarn shaved from the primary backing over
a unit area divided by the normal pile depth as represented by the
following formula: m p ##EQU1## where: [0050] m is the mass in
ounces of yarn over the primary backing in one square yard of
primary pile fabric; and [0051] p is the pile height in yards.
[0052] Preferably, surface covering elements for use in covering
relation to subfloors in a residential environment will be
characterized by a standard pile density in the range of about 500
ounces per cubic yard to about 4,200 ounces per cubic yard. More
preferably, surface covering elements for use in covering relation
to subfloors in a residential environment will be characterized by
a standard pile density in the range of about 1500 ounces per cubic
yard to about 3500 ounces per cubic yard. Most preferably, surface
covering elements for use in covering relation to subfloors in a
residential environment will be characterized by a standard pile
density in the range of about 2000 ounces per cubic yard to about
3,000 ounces per cubic yard.
[0053] By way of comparison, a standard pile face for use in a high
traffic hotel hospitality environment as sold under the trade
designation GRAND PLAZA by Milliken & Company is characterized
by a standard pile density of about 4,357.3 ounces per cubic
yard.
[0054] As will be appreciated, a higher pile height may be desired
in a residential environment than in a commercial or hospitality
environment. For residential applications it is believed that a
normal pile height above any primary backing is preferably in the
range of about 0.25 inches to about 0.75 inches and more preferably
about 0.3 inches to about 0.5 inches and most preferably about 0.4
inches. In this regard, It is to be understood that by the term
"normal pile height" is meant the naturally occurring level of yarn
over the primary backing. As illustrated in FIG. 13D, this normal
pile height may be less than the actual yarn length due to bending
as a result of texturing or twist in the yarn.
[0055] The primary backing 122 used in the tufted constructions of
FIGS. 13A, 13B and 13C may be a traditional woven or nonwoven
structure of polyester or polypropylene. However, it is also
contemplated that specialized primary backings such as non-woven
structures comprising fiberglass sandwiched between layers of
polyester may be utilized in the primary backing 122 of the tufted
constructions to impart the desired properties relating to
stability and cutability thereby potentially reducing or even
eliminating the need for adhesive pre-coat 124. Alternative primary
backing or tufting substrate embodiments are described, for
example, in pending U.S. patent application Ser. No. 10/098,053,
filed Mar. 12, 2002 the teachings of which are hereby incorporated
in their entirety as if fully set forth herein.
[0056] By way of example only and not limitation, according to one
contemplated practice, the primary backing 122 is a fused
multi-component structure of a woven layer and a non-woven material
needle punched through the woven layer, with at least a portion of
the non-woven material being a low melt or binder material which
when subjected to calendering (pressure and heat) melts and fuses
the non-woven and woven materials to form an enhanced stability
primary backing. The woven layer is a woven polypropylene, the
non-woven material is polyester, and the low melt material is low
melt or co-polyester. The weight percent range of low-melt or
binder material may range from about 10%-100% by weight of the
non-woven, preferably 10%-70%. most preferably 10%-40%. The
non-woven material may be any natural or synthetic fiber or blend
thereof. For example, the non-woven may be polyester, recycled
polyester, polypropylene, stabilized polypropylene, acrylic, nylon
(polyamide), bi-component polyester, bi-component nylon, and blends
or combinations thereof. If the non-woven material is a
polypropylene or stabilized polypropylene, then no additional low
melt material may be required. The low melt material may be any
synthetic material or fiber or blend that has a melting point below
the calendering temperature and will adhere to the adjacent fibers.
For example, the binder or low melt material may be polyester,
co-polyester, polypropylene, polypropylene that has been chemically
enhanced to raise the melt temperature, bi-component polyester,
bi-component nylon, polyethylene, nylon, low melt nylon web, powder
binder, chemical binder, extruded polypropylene web, and
combinations or blends thereof. The woven material may be any
natural or synthetic material or fiber or blend which serves as a
tufting base in combination with the non-woven and low melt
materials. For example, the woven material may be polypropylene,
stabilized polypropylene, flat ribbon yarn (tape) polypropylene,
polyester, polyester knitted scrim, polypropylene woven scrim,
recycled polyester, and blends or combinations thereof. In
accordance with one exemplary construction, the woven layer or
material may have a pick range of from about 6.times.6 to
30.times.30, preferably from about 10.times.10 to 24.times.22, the
non-woven material may have a weight range of about 1-6 oz./sq.
yd., with a low melt or binder content of about 10-100% by weight.
In accordance with one exemplary embodiment, an enhanced primary
backing 122 having an overall thickness of about 0.017 inches and
weight of about 5.03 oz./sq. yd. may be utilized. The primary
backing includes a woven, a non-woven material of blended, needled,
and fused thereto polyester and low-melt polyester fibers (50% by
weight natural polyester fibers 21/2 denier, 20% black polyester
fibers 4 denier, and 30% low melt polyester 3 denier) is formed by
placing the non-woven material over the woven layer, needle
punching the non-woven material to the woven layer such that a
small amount of the non-woven goes through the woven layer and then
calendering the composite on both sides (at a temperature of about
320.degree. F. top roller, 280.degree. F. bottom roller with roller
pressures of about 85 pounds force) force to fuse the non-woven
material and woven layer. This fused, enhanced stability primary
backing is less likely to fray when cut, does not harm the tufting
yarn, provides dimensional stability, and better tuft lock.
[0057] In tufted constructions, the adhesive pre-coat 124 is
preferably styrene butadiene rubber (SBR) or latex but other
suitable materials such as styrene acrylate, polyvinyl chloride
(PVC), ethylene vinyl acetate (EVA), acrylic, and hot melt
adhesives such as bitumen, polyurethane, polyester, polyamide, EVA,
or asphalt based hot melt adhesives or blends thereof may likewise
be utilized. In the event that a hot melt adhesive is utilized, it
is contemplated that a reinforcement material such as a fiberglass,
nylon or polyester scrim, woven or non-woven may be directly
attached to form a composite laminate without the use of additional
adhesive layers. Moreover, it is contemplated that the adhesive
pre-coat 124 may be entirely eliminated in the tufted product if
the pile yarn is tufted in suitably stable relation to the primary
backing 122 thereby yielding a construction as illustrated in FIGS.
16A-16C.
[0058] As previously indicated, it is contemplated that a surface
covering element construction according to the present invention
including either a tufted or a bonded primary pile fabric 112
across the surface facing away from the subfloor 111 preferably
includes a load distribution layer 157 at a position below the
primary pile fabric. By way of example only, it is contemplated
that the load distribution layer 157 may include one or more layers
of a resilient polymeric tie coat material 160. The polymeric tie
coat material 160 may be of either a thermoplastic or a
thermosetting composition. Hot melt adhesives may be particularly
preferred. By way of example only and not limitation, useful hot
melts may include bitumen and polyolefin-based thermoplastics.
Useful thermosetting adhesives may include polyurethanes. In the
event that the tie coat material 160 is a hot melt adhesive, it is
contemplated that the total mass of hot melt adhesive utilized
within the load distribution layer 157 will preferably be in the
range of about 20 to about 100 ounces per square yard and will more
preferably be present at a level of about 35 to about 90 ounces per
square yard.
[0059] The composition of one potentially preferred hot melt
adhesive is set forth in the following table. TABLE-US-00002 Hot
Melt Composition Component Percentage Asphalt 17.6% Stearic Acid
0.3% Heat Stabilizer 0.2% Antioxidant 0.1% Tackifier 3.0% Amorphous
Polypropylene 4.0% Acid Modified Polypropylene 2.0% Calcium
Carbonate Filler Remainder
[0060] The physical properties of the hot melt composition from the
above table are set forth below. TABLE-US-00003 Hot Melt Properties
Softening Point 314-320.degree. F. Cold Flow 2 to 5 mils per 4
hours Flex Mandrel 12 to 16 mm at 76 mils CR Viscosity (at 5
sec.sup.-1) 28,000 to 35,000 cps CS Viscosity (at 50Tau) 10,000 to
13,000 cps Tensile Strength .about.450 p.s.i. Elongation at Break
5.8%
[0061] If desired, a reinforcement material 158 may also be
disposed within the load distribution layer 157. In some
constructions, the reinforcement material may enhance dimensional
stability within the surface covering element to substantially
prevent the various layers from undergoing disproportionate
dimensional change as the surface covering element is subjected to
compressive forces and/or temperature or humidity changes during
use and/or processing. One contemplated reinforcement material 158
is a sheet, mat or tissue incorporating multiple fiberglass (glass)
fibers entangled in a non-woven construction such as a 2
oz/yd.sup.2 construction and may be held together by one or more
binders such as an acrylic binder or modified acrylic binder. Other
materials as may be utilized include woven glass or glass scrim
materials as well as woven or non-woven textile materials such as
polyester or nylon. If desired, it is also contemplated that the
reinforcement material 158 may be eliminated such that the load
distribution layer is made up substantially entirely of the tie
coat material.
[0062] Whether or not a reinforcement material 158 is utilized, the
load distribution layer 157 nonetheless acts to disperse
concentrated loads laterally through the surface covering element
thereby dissipating the applied energy and preventing the structure
from being damaged. In operation, the tie coat material 160 acts as
a buffer against force concentration and will protect any
reinforcement material 158 against puncture or other damage which
may arise from point loading. By way of example, the load
distribution layer must have sufficient strength and resiliency
such that a small diameter shoe heel or other force concentrating
object does not puncture the construction.
[0063] As indicated, the cushioning material 178 may be a foam
material. Potentially preferred foam materials may include virgin
or prime polyurethane, rebonded polyurethane and combinations
thereof. Rebonded polyurethane may be particularly preferred so as
to permit the surface covering elements to incorporate a relatively
high percentage of recycled material.
[0064] As will be appreciated, rebond foam in general and rebond
polyurethane foam in particular is known in the art of
isocyanate-based polymeric foams. Specifically, it is known to mix
pieces of foam with a binder which serves to bond the pieces to one
another. Rebonding technology has been used for a number of years
to recycle, inter alia, polyurethane foams. Generally, a large chip
or chunk size, low density, non-uniform density, rather frangible,
thick, rebonded polyurethane foam product has been used as a
separate, relatively thick, underlayment or pad for broadloom
carpet placed across a subfloor.
[0065] In accordance with the present invention, the cushioning
material 178 in the surface covering element preferably
incorporates at least about 10-90% recycled foam or rebond foam
containing at least about 10-100% recycled foam chips, chunks,
pieces, grounds, particles, or the like and a binder, adhesive, or
prepolymer (and one or more additives) to produce a construction
with an integral cushioning layer having at least about 10-100%
recycled foam or cushion content (especially post industrial
reclaimed foam or cushion content) in the foam or cushion layer
thereof.
[0066] In accordance with the present invention, it is preferred to
use a rebond foam with a density of about 1 to 25 lbs per cubic
foot, more preferably about 3-22 lbs. per cubic foot, still more
preferably 5-13 lbs. per cubic foot, and most preferably 6-10 lbs.
per cubic foot; a thickness of about 1-30 mm, more preferably about
2-21 mm, and most preferably about 4-12 mm; a rebond chip size
(uncompressed chip size) of about 2-25 mm, more preferably about
5-20 mm, most preferably about 7-15 mm round or square hole mesh;
and, a backing material or backing composite on at least one side
thereof.
[0067] Table 1 below details a first exemplary range of production
parameters for rebond foam for use as a cushioning layer in a
modular floor covering to be used in a residential environment.
TABLE-US-00004 TABLE 1 Foam Weight 7-84 oz/yd.sup.2 Foam Density
4-16 lbs./ft.sup.3 Foam Thickness (prelamination) 2-20 mm
Uncompressed Chip Size 2-20 mm Chip Material Polyurethane Foam
(polyester or polyether) Binder or Prepolymer 5-20% Chips 60-95%
Binder Material Polyurethane Prepolymer (polyester or polyether)
Compression Ratio 2:1-5:1 Additives such as colorant, fill, fiber,
0-20% antimicrobial, flame retardant, etc.
[0068] Table 2 below details a second exemplary range of production
parameters for rebond foam for use as a cushioning layer in a
modular floor covering to be used in a residential environment.
TABLE-US-00005 TABLE 2 Foam Weight 10-28 oz/yd.sup.2 Foam Density
5-10 lbs./ft.sup.3 Foam Thickness (prelamination) 5-12 mm
Uncompressed Chip Size 5-15 mm Chip Material Polyurethane Foam
(polyester or polyether) Binder or Prepolymer 12-17% Chips 83-88%
Binder Material Polyurethane Prepolymer (polyester or polyether)
Compression Ratio 3:1 Additives such as colorant, fill, fiber, etc.
0-5%
[0069] Tables 3-5 set forth target specifications for rebond foam
materials which may be used in various modular residential floor
covering structures. TABLE-US-00006 TABLE 3 Foam Density 6
lbs./ft.sup.3 Foam Thickness 7-8 mm (prelamination) Uncompressed
Chip Size 15 mm Chip Material Polyurethane Foam Binder or
Prepolymer 15% by weight Chips 82-85% by weight Binder Material
Polyurethane Prepolymer Compression Ratio 3:1 Colorant (may be
added) Milliken Reactint polyurethane colorant at about 3%
[0070] TABLE-US-00007 TABLE 4 Foam Density 6.3 lbs./ft.sup.3 Foam
Thickness (prelamination) 7 mm Uncompressed Chip Size 7 mm Chip
Material Polyurethane Foam Binder or Prepolymer 15% by weight Chips
(free of unbonded material) 82-85% by weight Binder Material (free
of binder knots) Polyurethane Prepolymer Compression Ratio 3:1
Colorant (may be added) Milliken Reactint polyurethane colorant at
about 3%
[0071] TABLE-US-00008 TABLE 5 Foam Density 3 lbs./ft.sup.3 Foam
Thickness (prelamination) 6 mm Uncompressed Chip Size 5 mm Chip
Material Polyurethane Foam Binder or Prepolymer 15% Chips 82-85%
Binder Material Polyurethane Prepolymer Compression Ratio 2:1
Colorant (may be added) Milliken Reactint polyurethane colorant at
about 3%
[0072] As will be appreciated, while rebond foam as described above
may be preferred, it is contemplated that the material forming the
cushioning layer 178 may be the subject of a broad range of
alternatives. By way of example only and not limitation, at least
five options or examples of foam for use in forming the cushion
material 178 are contemplated for forming the surface covering
elements. [0073] 1. Use of standard filled Polyurethane system as
the virgin and/or rebond polyurethane. One contemplated
polyurethane foam contains 110 parts of filler and has a density of
about 15 lbs/cu. ft. Based upon a thickness in the range of
0.04-0.12 inches, using the density and filler levels above, the
weight range of the polymer is about 4.32 oz/sq yd to 12.96 oz/sq
yd. The density can be lowered by lowering the amount of filler.
[0074] 2. Another option which would also work for the virgin
and/or rebond polyurethane is to adjust the filler levels to reduce
the density to 13 lbs/cu. ft. At the same thickness limits the
polymer weights would then be 2.72-8.24 oz/sq. yd. [0075] 3.
Another option for the virgin and/or rebond polyurethane is 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. Based upon a prime at 6 lbs/cu. ft. applied at the
thickness limits above the polymer weight would be 2.88-8.64 oz/sq.
yd. [0076] 4. Another option is to use a polyurethane system
available under the trade designation KANGAHIDE by Textile Rubber
and Chemical Company which has only 15 parts of a filler material
and is applied at 6-9 lbs/cu. ft. density may be used. If a polymer
calculation is again made at the described thickness limits it
would be 4.3-13.02 oz/sq. yd. [0077] 5. Another option is to use a
medium density or hybrid foam formed of mechanically frothed and
chemically blown polyurethane foams. Such a mechanically frothed
and chemically blown polyurethane foam is described, for example,
in U.S. Pat. No. 6,372,810 hereby incorporated by reference
herein.
[0078] The density of filled prime or virgin polyurethane foams can
be controlled by limiting the amount of filler. For example, one
can reduce the filler content to produce a prime polyurethane foam
of about 6 lb. per cubic foot density.
[0079] Although the above examples have to do with polyurethane, a
water based foam system can also be used. For example, the foam may
be an SBR foam. Although a virgin polyurethane or polyurethane
rebond foam or compressed particle foam (formed of compressible
particles, chips, crumbs, etc.) may be preferred, it is to be
understood that other compressible particles made from other foams
(open cell, closed cell) or materials such as SBR foam, PVC foam,
polyethylene foam, cork, rubber, crumb rubber, and/or the like may
also be used. In particular, it is contemplated that in place of
form, a felt or non-woven cushion may be utilized.
[0080] Regardless of the cushioning material used, it is
contemplated that such material will preferably be characterized by
a compression modulus such that a relatively soft feel is imparted
to the user. By way of example only, it is contemplated that the
cushioning material will preferably be characterized by a 50%
compression at a load of between about 5 and about 70 psi and more
preferably about 10 to about 30 psi when the isolated cushioning
material is measured according to ASTM specification D3574 Test C
(Compression Force Deflection Test).
[0081] As previously indicated, surface covering elements of any of
the described constructions may include an optional backing layer
170 also referred to as a release layer or secondary backing. The
optional backing layer 170 is preferably a woven or non-woven
textile fabric of polyester, polypropylene,
polyester/polypropylene, polyester/polypropylene/acrylic, or other
appropriate fibers or blends and may contain a colorant, binder, or
the like. According to one contemplated practice, the backing layer
170 may be a non-woven structure or felt of polyester fiber and
polypropylene fiber, with about 50%-100% polyester. In another
embodiment, a blend of 50% polyester fiber, 20% polypropylene, and
30% acrylic fibers may be used. The polyester, polypropylene and/or
acrylic fibers may be of one or more selected colors to give the
backing a desired color or appearance. In one embodiment, foam
forming the cushioning layer and the backing layer 170 have a
similar color. In a particular example, the foam and/or backing
have a green, blue, purple, gray, white, black, brown, or gold
color. The color of the backing can be achieved, for example, by
using a white polyester fiber and a colored acrylic fiber or by
using colored polyester and/or polypropylene fibers. In accordance
with another example, an amount of black polyester fibers is
blended with an amount of white polyester fibers, an amount of
colored polyester fibers, and an amount of white polypropylene
fibers to form a non-woven colored backing material or felt having
the color of the colored polyester fibers and having a heathered or
speckled look. The respective amounts of each type or color of
fiber are selected to give the desired color, brightness, shrink,
etc. If desired, the surface covering elements of any of the
described constructions may also include an optional friction
enhancing coating 180 (FIG. 13D) which may be applied in either a
substantially continuous or patterned arrangement. By way of
example only and not limitation, such friction enhancing coatings
may include latex, hot melt adhesives, and the like. Also, although
it is not preferred, the coating 180 may be covered with a release
sheet, layer or film.
[0082] According to one contemplated practice, the constructions
forming the surface covering elements may be formed by a production
process as shown in FIGS. 14A and 14B. According to this practice,
a backing composite made up of the backing 170, the cushioning
layer of foam 178 and the layer of reinforcement material 158 are
flame laminated into a coordinated composite (FIG. 14A).
Thereafter, as illustrated schematically in FIG. 14B, the formed
composite is adjoined to the underside of the primary carpet fabric
112 by the tie coat adhesive 160. The formed structure is
thereafter cooled and cut to a desired shape. As will be
appreciated, while this process makes use of a preformed foam
cushioning layer it is likewise contemplated that the same
structures may be formed utilizing continuous, in-line or in-situ
formation practices. Such practices are illustrated and described
in U.S. Pat. No. 6,203,881 to Higgins et al. the teachings of which
are incorporated by reference as if fully set forth herein.
[0083] As will be appreciated, there exist a substantial number of
alternative embodiments and configurations for layered
constructions forming the surface covering elements for use in the
flooring system of the present invention. By way of example only,
in FIGS. 15A, 15B, 15C and 15D wherein elements corresponding to
those previously described are designated by like reference
numerals in a 500 series, pile constructions are illustrated
corresponding substantially to those in FIGS. 13A-D respectively
but wherein the reinforcing material 558 as previously described is
held in suspended relation between layers of tie coat material such
as the hot melt adhesive previously described. In such a
construction, it is contemplated that the tie coat material 560 may
be either in substantially discrete layers separated by the
reinforcement material 558 or may migrate across the reinforcement
material 558. In either event, due to the substantial adhesion
between the tie coat material 560 and the reinforcement material
558, a substantially stable load distribution layer 557 is
nonetheless established in bonding relation between the primary
pile fabric 512 and the cushioning material 578. Of course, if
desired a fiction enhancing coating as previously described may be
disposed across the underside of the backing 570.
[0084] In accordance with one example and with reference again to
FIGS. 15A-15D, the reinforcement material 558 may be a glass mat
which is hot melt laminated to the foam 578 by a hot melt layer
560.
[0085] As illustrated in FIGS. 16A, 16B and 16C, wherein like
components to those previously described are designated by
corresponding reference numerals within a 600 series, it is
contemplated that tufted loop pile and tufted cut pile
constructions 610A and 610B may include a first layer of tie coat
material 660 such as hot melt adhesive or the like extending away
from the primary backing 622 and into contact with a sheet of
reinforcement material 658 such as the non-woven glass or scrim
material previously described. Thus, the tie coat material 660
serves the function of securing the tufts 620, 621 in place
relative to the primary backing 622 thereby avoiding the need to
utilize a separate latex or hot melt pre-coat. Accordingly, a
single adhesive layer extends between the upper surface of the
reinforcement material 658 and the underside of the primary backing
622. Of course, if desired a fiction enhancing coating as
previously described may be disposed across the underside of the
backing 670.
[0086] As illustrated in FIGS. 17A, 17B and 17C wherein like
components to those previously described are designated by
corresponding reference numerals within a 700 series, it is
contemplated that tufted loop pile construction 710A, tufted cut
pile construction 710B, and bonded cut pile construction 710C
include a first layer of a tie coat material 760 extending away
from the upper surface of a layer of reinforcement material 758 and
which may be of a different character from a second layer of tie
coat material 760' extending away from the lower surface of the
reinforcement material. In all other respects, the configuration is
substantially as illustrated and described in relation to FIGS.
16A, 16B and 16C respectively. By way of example only and not
limitation, in the event that the reinforcement material 758 is
disposed between two different adhesives, it is contemplated that
the tie coat material 760 extending away from the upper surface of
the reinforcement material 758 may be, for example, hotmelt, while
the tie coat material 760' extending away from the lower surface of
the reinforcement material 758 may be, for example, polyurethane
forming composition, a low melt powder, low melt fibers, a low melt
film, or the like. Of course, the tie coat material 760 and/or 760'
may also comprise multiple layers of the adhesive. If desired, a
fiction enhancing coating as previously described may be disposed
across the underside of the backing 770.
[0087] In FIGS. 18A, 18B and 18C wherein like components to those
previously described are designated by corresponding reference
numerals within an 800 series, there are illustrated yet additional
constructions for forming surface covering elements for use in
covering a subfloor. In such embodiments, tufted loop pile
construction 810A and tufted cut pile construction 810B, 810C
include a layer of reinforcement material 858 disposed between a
first layer of latex adhesive 824 extending away from the upper
side of the reinforcement material 858 and a second layer of latex
adhesive 824 extending away from the lower side of the
reinforcement material 858. Thus, latex extends substantially
between the upper surface of the cushion material 878 and the
primary backing 822 with the layer of reinforcement material 858
disposed within such latex at an intermediate position. Such latex
is preferably a carboxilated styrene butadiene rubber (SBR) latex.
Of course it is also contemplated that similar constructions
utilizing other adhesives such as Polyvinyl chloride (PVC),
ethylene vinyl acetate (EVA), and acrylics as well as hot melts or
polyurethanes as previously described may be useful. Of course, if
desired a fiction enhancing coating as previously described may be
disposed across the underside of the backing 870.
[0088] As previously indicated, it is contemplated that additional
stability may be introduced by incorporating stabilizing elements
in intimate relation to the primary backing of a tufted primary
pile fabric. Exemplary embodiments incorporating such a
configuration are illustrated in FIGS. 19A, 19B and 19C wherein
like components to those previously described are designated by
corresponding reference numerals within a 900 series. As
illustrated therein, tufted loop pile construction 910A and tufted
cut pile construction 910B, 910C include pile forming yarns 920,
921, 921' tufted through a primary backing 922 which incorporates
therein a primary backing stabilizing layer 923 such as a woven or
non-woven material or scrim. The primary backing stabilizing layer
923 may be adjoined to the primary backing 922 by a needling or
calendering operation. In addition, point bonding may be achieved
between the structures by incorporating heat activated adhesive
fibers within the non-woven construction. In the event that a
construction incorporating a primary backing stabilizing layer is
utilized, it is contemplated that the pre-coat 924 and/or the
reinforcement material 958 may be substantially reduced or
eliminated entirely if desired due to the stability imparted to the
enhanced primary backing 922, 923. If desired, a fiction enhancing
coating as previously described may be disposed across the
underside of the backing 970.
[0089] As will be appreciated, while the secondary backing or felt
may be flame laminated to the underside of the cushioning material,
it is also contemplated that other attachment mechanisms may be
used if desired. By way of example only, it is contemplated that
the secondary backing may be joined to the underside of the
cushioning material by one or more layers of adhesive such as hot
melt adhesive or the like as previously described. Exemplary cut
pile constructions 1010A, 1010B for a surface covering element
disposed in overlying relation to a subfloor 1011 are illustrated
in FIGS. 20A and 20B, wherein elements corresponding to those
previously described are designated by corresponding reference
numerals within a 1000 series.
[0090] In accordance with yet another embodiment as shown in FIG.
21, which corresponds to FIG. 13D, the reinforcement material or
layer 158 of load distribution layer has been eliminated. In this
embodiment, the tie-coat lay 160 serves as the load distribution
layer.
[0091] With reference to FIG. 22 which corresponds to FIG. 13D,
still another embodiment is illustrated in which the backing layer
of felt or other material 170 of FIG. 13D has been eliminated.
[0092] With reference to FIG. 23 which corresponds substantially to
FIG. 19, in still yet another embodiment, the pre-coat layer 924,
tie-coat layers 960, reinforcement layer 958, and backing layer 970
have been eliminated. The foam layer 978 may be adhered to the
primary carpet fabric 921', 922, 923, for example, by flame
lamination or by being applied directly thereto in a wet or uncured
state and then cured.
[0093] The surface covering elements in the flooring system
according to the present invention are preferably suitable for
installation in a residential environment by a user with little or
no experience with flooring installations. So as to improve the
ease of installation, the surface covering elements disposed across
the subfloor are preferably resistant to sliding movement across
the subfloor once they are placed in position without the need for
separately applied adhesives. However, the surface covering
elements are preferably readily displaceable vertically away from
the subfloor to facilitate replacement or repositioning during
installation. As will be appreciated, the ability to lift and move
the surface covering element to various positions across the
subfloor a number of times without damaging either the surface
covering element or the subfloor may be particularly desirable for
an unskilled installer. In addition, in a residential environment,
the ability to remove and replace or clean a stained or damaged
surface covering element at an extended time after installation is
desireable. Thus, in accordance with a potentially preferred
practice, any friction enhancing coating disposed across the
backing is preferably of a character which does not permanently
bond to the subfloor. In addition, it is desirable that the
friction enhancing coating does not permanently stick to itself so
as to avoid undesired blocking attachment in back to back packaging
(FIG. 25). Still further, it is desirable that any friction
enhancing coating should not adhere to the surface of the primary
carpet fabric so as to avoid undesired permanent adhesion if the
surface covering elements are stored in roll form or stacked face
to back (FIG. 26). That is, the friction enhancing coating
preferably provides lateral grip with little or no vertical stick
and with little or no blocking to itself or the face of the primary
pile fabric.
[0094] The evaluation of various friction enhancing coating
materials was carried out by conducting sliding friction and
blocking tests in accordance with the following procedures.
[0095] Friction tests were performed by placing a 3''.times.3''
piece of coated carpet tile on a smooth flat surface (a piece of
laminate wood-like flooring). One end of the flat surface was
raised at a rate of .about.10 degrees per second. The center of the
carpet tile was always placed 10 inches from the pivot point. The
angle at which the carpet tile began to slip was recorded. No
weight or pressure was applied to the sample, and both surfaces
were visually inspected to be clean before the measurement was
performed. Error bars are 5 degrees.
[0096] Instantaneous blocking tests were performed by placing two
identically coated 3''.times.3'' carpet tiles back-to-back with a 5
lb weight applied for 1 minute. A strip of aluminum foil was used
to mask 1/2 inch of one edge. The force required to pull the
samples apart was measured using an AccuForce III force meter from
AMETEK.
[0097] Elevated temperature blocking tests at 70 degrees C. (158
degrees F.) were performed by placing two identically coated
3''.times.3'' carpet tiles back-to-back with a 6.25 lb weight
applied for at least 16 hours in a 70 C. oven. A strip of aluminum
foil was used to mask 1/2 inch of one edge. After removing from the
oven, samples were allowed to cool. They were pulled apart by
pulling on the edge carpet tufts from the masked side of the tiles
using an AccuForce III force meter from AMETEK. The peak force
needed to separate the tiles was recorded.
[0098] Re-Stick friction tests were conducted to determine the
reusability of the carpet friction enhancing or grip layer. A
3''.times.3'' piece of coated carpet was placed on clean, laminate,
wood-like flooring with a 5-lb weight applied. After 30 seconds,
the weight and carpet were moved to a fresh section of the
flooring. This was repeated such that the carpet was exposed to 5
positions. The results of a friction test as described above were
then recorded.
[0099] Each of the above tests were carried out on samples of
carpet tile having a construction substantially as set forth in
Example 5 below. The coating in sample 1 was a latex marketed by
National Starch & Chemical under the trade designation
MULTILOCK 454A. The coating in sample 2 was a latex marketed by
Rohm and Haas under the trade designation ROBOND PS-68. The coating
in sample 3 was a latex marketed by Air Products and Chemicals
under the trade designation AIRFLEX TL12. The coating in sample 5
was a hot melt adhesive marketed by H. B. Fuller under the trade
designation HL6102. Control sample 5 was uncoated. The results are
set forth in the following table. TABLE-US-00009 Friction 70 deg C.
on Re-Stick Dry add- Instantaneous Blocking Laminate Friction
Sample on (gms) Blocking (lbs) (lbs) (degrees) (degrees) 1 30
<0.7 <0.7 85 80 2 20 0.7 1.3 48 45 3 30 4.8 60 4 20 <0.7
2.7 45 45 5 0 <0.7 <0.7 20 20
[0100] Based upon these tests it was concluded that samples 1 and 2
exhibited potentially desirable friction and anti-blocking
characteristics with sample 4 being adequate and sample 3 being
undesirable. Of course, the samples tested are merely
representative and other suitable coating materials no doubt exist.
Exemplary materials may include various classes of latex including
acrylics, EVA, SBR, and the like and hot melt materials including
polyolefins, EVA, SBR, polyamides, and the like. Potentially
preferred coating materials may include latex. The dry add-on
ranges should preferably be less than about 65 gms per square
meter, more preferably less than about 30 grams per square meter
and most preferably less than about 20 grams per square meter.
[0101] The friction enhancing or grip reducing coatings may be
applied to the back of the surface covering elements by various
methods including roll coating, spray coating, impregnation, powder
coating, and printing methods. After application of the coating, a
drying and or curing process may be used depending on the form of
the coating chosen.
[0102] Although a friction enhancing coating or chemical treatment
is preferred, it is contemplated that one may use another
releasable adhesive or material such as double sided tape, hook and
loop releasable materials, spray adhesives, and the like.
[0103] As will be appreciated, due to the fact that the surface
covering elements in the flooring system of the present invention
are intended to support users who walk across the surface, it may
be desirable to provide a controlled degree of cushioning within
the various components of the surface covering construction to
provide a controlled degree of cushioning to the users. It is
believed that the cushioning function in the overall construction
is derived from both the outwardly projecting yarns within the
primary pile fabric 112 as well as from the foam or other
cushioning material 178 disposed below the force distribution layer
157. Thus, the pile structure and cushioning material should be
characterized by a sufficient deformation under load such that the
final resulting desired level of compression is achieved.
[0104] As will be appreciated, compressibility character may be
evaluated by a standard force deflection test such as set forth at
ASTM Standard D-3574 Test C--Compression Force Deflection Test. By
way of example only, and not limitation, in order to provide a
desired degree of cushioning as may be required in a residential
application, it is believed that the overall multi-layer
construction 110A-D forming the surface covering element is
preferably characterized by a compression modulus such that it is
compressed at least 60% when subjected to an applied load of
between about 150 to about 1000 psi.
[0105] As previously indicated and in accordance with at least one
embodiment, there is preferably no visible seam between adjacent
surface covering elements once they are installed across the
subfloor. It is believed that the ability to reduce the appearance
of visible seams may be enhanced by the combination of yarn
coloration, surface character and edge cut character of the surface
covering elements.
[0106] As regards coloration, it is contemplated that the
individual surface covering elements may be either patterned or may
have a substantially uniform coloration across the surface. In the
event that the surface covering elements are intended for
residential application, a substantially uniform coloration may be
preferred so as to reduce installation complexity. However, it is
believed that a heather or mottled coloration may be useful in
reducing seam appearance. The application of such heather
coloration schemes is disclosed in pending U.S. patent application
Ser. No. 10/139,019 filed May 3, 2002 and Ser. No. 10/167,185 filed
Jun. 11, 2002 the teachings of both of which are incorporated by
reference in their entirety as if fully set forth herein. As
regards surface character, the hiding of seams is believed to be a
function of both the length of the yarn and the filling character
of the yarn along the edge. The filling character of the yarn is,
in turn, a function of both the bulk of the yarn as well as the
normal density of the yarns disposed along the edge. By the term
"normal density" is meant the population density prior to any
damage from cutting.
[0107] The following table outlines exemplary and potentially
preferred construction features for a pile fabric of tufted
construction which are believed to provide the desired surface
character to hide seams between the various tiles.
[0108] As previously noted, the yarns utilized preferably
incorporate a substantial degree of twist which adds to the bulk of
the yarns due to the kink at the terminal ends of the yarns. As
will be appreciated, this kinking gives rise to a phenomenon
wherein the naturally occurring pile height is actually less than
the extended length of the yarns forming the pile. That is, the
individual yarns forming the pile may be pulled straight to extend
past the height of the surrounding pile yarns. As indicated
previously, this phenomenon lends a substantial cushioning effect
to the primary pile fabric. This kink also causes portions of the
pile yarns immediately adjacent to the edge of the surface covering
element to extend outboard of the edge and to intermingle with
complimentary outwardly extending portions of edge yarns on the
immediately adjacent surface covering element. In order to provide
this cross-over bridging engagement, the yarn within the primary
pile fabric is preferably characterized by an extended length above
the primary backing in the range of about 0.25 inches or higher and
more preferably in the range of about 0.4 to about 1.5 inches and
most preferably in the range of about 0.6 inches. In this regard,
it is to be understood that by the term "extended length" is meant
the length of the yarn above the primary backing when the yarn is
pulled straight.
[0109] In order to reduce seam appearance, it is also believed to
be important to avoid substantial damage of the pile forming yarns
in the region immediately adjacent to the edge. That is, the yarns
at the edge are preferably not sheared or pulled out of the primary
backing during cutting. In order to evaluate the integrity of edges
in surface covering elements incorporating pile fabric coverings,
the following procedure has been developed. [0110] 1. Arrange the
element to be analyzed such that the edge of interest can be easily
viewed at 9.times.. The sample must be able to be moved smoothly
under the microscope, so as to make a count along a significant
length (at least 6 or more inches, for example). Decide upon an
appropriate length of edge upon which to make a count. Measure that
length and establish the beginning and ending point for the
observations to be made. [0111] 2. Begin at one end of the distance
to be measured and move sequentially from yarn to yarn along that
length. Examine each yarn along the length. [0112] 3. During
examination only consider those yarns that are immediately adjacent
to or involved in the actual cut. Yarns not at the edge (behind
another, for example) are not considered as appropriate to count.
Yarns that have been cut below the surface (within the adhesion
material) and having no protruding filaments are not considered in
these counts. [0113] 4. Gently move each yarn, as necessary, to
determine if any of the filaments that comprise it have been cut.
If more than three of the filaments have been completely severed,
that yarn is determined to be `cut` yarn and is counted as such.
[0114] 5. Determine the `cut status` (cut or not cut) for that
particular yarn, then move to the next adjacent yarn. Continue
until you reach the end of the distance over which you wish to make
counts. [0115] 6. By dividing the total number of affected (cut)
yarns by the measured distance of the edge involved, compute the
number cut per unit length for that edge. [0116] Edge character
evaluated according to the above method is preferably such that
less than about 50 percent of the piles along the edge are cut and
more preferably less than about 40% of the piles along the edge are
cut and most preferably less than about 25% of the piles along the
edge are cut.
[0117] In order to prevent edge yarns from being cut, it is
contemplated that the individual surface covering elements be
stamped or cut from a precursor or composite of larger dimensions
by controlled depth cutting from the back using, for example,
controlled depth die cutting (FIGS. 24A, 24B) using a displaceable
strike plate 61 that extends during cutting (FIG. 24B) such that a
plurality of supporting pin elements 63 define the supporting
surface surrounding the cut edge during the cutting operation. The
preferred die cut blade is a steel rule die with scalloped or
serrated edges. Other forms of cutting such as laser, water jet,
rotary reciprocating blade, band saw, and the like may be used.
[0118] By using a dye cutting procedure as illustrated in FIGS. 24A
and 24B it has been found that the percentage of cut piles in the
vicinity immediately adjacent the edge of the resulting segmented
material can be dramatically reduced. By way of example only, the
following table sets forth the results of an analysis of exemplary
tufted pile material controlled depth cut from behind in comparison
to similar tufted pile materials cut completely through from the
face. The analysis was carried out using the procedure as outlined
above. TABLE-US-00010 Cut Pile Evaluation End Cuts Cross Tufting
Direction Total Total Total Counted Cut Counted Total Cut End 1*
End 1* End 2** End 2** Front Cut 137 114 83.2% 93 18 19.4% Sample A
Front Cut 141 92 65.2% 111 23 20.7% Sample B Back Cut 99 19 19.2%
95 15 15.8% Sample A Back Cut 99 23 23.2% 102 14 13.7% Sample B
*End with yarns bent towards edge. **End with yarns bent away from
edge.
[0119] Thus, by incorporating controlled depth rear cutting that
cuts through the primary backing but not the face yarns, tuft
damage adjacent to the edge may be substantially reduced to about
25% or less.
[0120] While various potentially preferred constructions have been
illustrated and described, it is contemplated that a wide range of
alternatives may exist within the scope of the present invention.
By way of example only, and not limitation, the following table
details various contemplated variants for each component in a
surface covering composite as previously described. TABLE-US-00011
(A) (B) Possible Range 1. Product Type: Residential Modular Product
Low High 2. Face: loop pile, cut & loop pile, tufted cut-pile,
bonded cut-pile, woven, knit, nonwoven, or textured pile 3. Primary
Nonwoven polyester, nonwoven polypropylene, Backing: or woven
propylene with nylon needlepunched cap, woven polypropylene with a
polypropylene cap, woven polypropylene with a polyester cap and low
melt polyester binder 4. Total Finished oz/yd.sup.2 12 70 Yarn
Weight: 5. Stitches Per 5 14 Inch: 6. Tufting Gauge: 1/8, 1/10,
5/64 5/32 1/10 7. Yarn Polymer: Nylon 6,6, Nylon 6, Polyester,
Polypropylene, Wool, or Wool/Nylon blend 8. Yarn Type: Filament,
spun, or staple 900 2800 9. Yarn Twist: 3 8 10. Yarn Ply: Twisted -
2 ply, 3-ply, 4 ply, unplied singles yarn, or air entangled yarn;
Cabled - 2 ply, 3 ply or 4 ply 11. Heatset: Heatset or non heatset
yarn; heatset frieze 250 275 without steam 12. Yarn Size: 2.90/2
1.90/2 13. Tufted Pile Inches 1/8 2 Height: 14. Dyeing Method Jet
dye, flood dye, yarn dye, space dye, combination flood dye &
jet dye, or beck dye (may also be printed or graphics tufted) 15.
Precoat Styrene Butadiene Latex, hot melt, ethyl vinyl 8 40
Adhesive: acetate, acrylic, polyvinyl chloride, or no precoat
adhesive (may include anti-microbial agent) 16. Lamination Hotmelt
with a bitumen and polypropylene Tiecoat resin base, polypropylene
hot melt, bitumen Adhesive: hot melt, polyethylene hot melt, or
polyurethane styrene butadiene rubber 17. Upper Tiecoat oz/yd.sup.2
20 70 Coating Weight: 18. Stabilizing Fiberglass mat with modified
acrylic binder, no 0.9 oz./yd..sup.2 3.5 oz./yd..sup.2
Reinforcement: reinforcement, fiberglass scrim, polyester scrim, or
fiberglass mat with urea formaldehyde binder or melamine binder 19.
Lower Tiecoat oz/yd.sup.2 (or flame lamination) 0 35 Coating
Weight: 20. Cushion Type: Rebond polyurethane foam, virgin filled
polyurethane foam, prime polyurethane foam, styrene butadiene
rubber foam, polyethylene foam, polyvinyl chloride foam, or
nonwoven felt 21. Cushion Millimeters (prelamination) 1 18
Thickness 22. Cushion Density lbs/ft.sup.3 5 25 23. Release Layer
Nonwoven or woven construction: 24. Release Layer % polyester/%
polypropylene blend 0%/100% 100%/0% composition 25. Release Layer
oz/yd.sup.2 1 6 weight: 26. Modular Shape: square, rectangle,
single chevron, two sided double chevron, four sided double
chevron, hexagon, single chevron, multi-chevron, double axe head,
tomahawk, sine wave edge (double- sided or four sided), bone, etc.
27. Modular Size: Inches per side (or inches of width for roll 4 72
product) 28. Cutting Method: Controlled depth or full depth 29.
Preferred Colors Solids (Beige, Green, Blue, Gray, Pink, Brown,
Taupe, White, Red), heathers, patterns, designs, or combinations
thereof
[0121] The present invention may be further understood by reference
to the following non-limiting examples:
EXAMPLES 1-5
[0122] The following examples set forth production specifications
or overall floor covering composite constructions
Example 1
[0123] TABLE-US-00012 (A) (B) 1. Product Type Residential Modular
Floor Covering 2. Face: High Twist Frieze Cut pile 3. Primary
Backing: Woven polypropylene (PolyBac - 4 oz/yd.sup.2) 4. Total
Finished 38 oz/yd.sup.2 Yarn Weight: 5. Stitches Per Inch: 7.81 6.
Tufting Gauge: 1/8 7. Yarn Polymer: Nylon 6,6 8. Yarn Type: 1180
filament, with antistat, semi dull trilobal, 17 dpf 9. Yarn Twist:
7.50 twist per inch in singles (S) and ply (Z) 10. Yarn Ply: 2 ply
twisted 11. Heatset: Yes, @ 260 to 264.degree. F. with steam frieze
12. Yarn Size: 3.69/2 cotton count 13. Tufted Pile Height: 48/64
inches (3/4'') 14. Dyeing Method Jet Dye 15. Precoat Adhesive:
Styrene Butadiene Latex, 12 oz/yd.sup.2 coating weight 16.
Lamination Hotmelt with a bitumen and polypropylene Tiecoat
Adhesive: resin base, 17. Upper Tiecoat 46 oz/yd.sup.2 Coating
Weight: 18. Stabilizing Fiberglass Mat, 2 oz/yd.sup.2, modified
acrylic Reinforcement: binder 19. Lower Tiecoat 15 oz/yd.sup.2
Coating Weight: 20. Cushion Type: Rebond polyurethane foam, 7
millimeter uncompressed chip size 21. Cushion 7 millimeter
(prelamination) Thickness 22. Cushion Density 9 lbs/ft.sup.3 23.
Cushion Weight 30 oz/yd.sup.2 24. Backing Layer Nonwoven felt
construction: 25. Backing Layer 70% polyester/30% polypropylene
blend composition 26. Backing Layer 4 oz/yd.sup.2 weight: 27.
Modular Shape: 18'' square or nominal 18'' .times. 19'' two-side
double chevron 28. Modular Size: 18'' square or nominal 18''
.times. 19'' 29. Cutting Method: Controlled Depth cut from the
back
Example 2
[0124] TABLE-US-00013 (A) (B) 1. Product Type Residential Modular
Floor Covering 2. Face: High Twist Frieze Cut pile 3. Primary
Backing: Woven polypropylene (PolyBac - 4 oz/yd.sup.2) 4. Total
Finished 38 oz/yd.sup.2 Yarn Weight: 5. Stitches Per Inch: 7.81 6.
Tufting Gauge: 1/8 7. Yarn Polymer: Nylon 6,6 8. Yarn Type: 1180
filament, with antistat, semi dull trilobal, 17 dpf 9. Yarn Twist:
7.50 twist per inch in singles (S) and ply (Z) 10. Yarn Ply: 2 ply
twisted 11. Heatset: Yes, @ 260 to 264.degree. F. with steam frieze
12. Yarn Size: 3.69/2 cotton count 13. Tufted Pile Height: 48/64
inches (3/4'') 14. Dyeing Method Jet Dye, 15. Precoat Adhesive:
Styrene Butadiene Latex, 12 oz/yd.sup.2 coating weight 16.
Lamination Hotmelt with a bitumen and polypropylene Tiecoat
Adhesive: resin base, 17. Upper Tiecoat 46 oz/yd.sup.2 Coating
Weight: 18. Stabilizing Fiberglass Mat, 2 oz/yd.sup.2, modified
acrylic Reinforcement: binder 19. Lower Tiecoat 15 oz/yd.sup.2
Coating Weight: 20. Cushion Type: Rebond polyurethane foam, 7
millimeter uncompressed chip size 21. Cushion 7 millimeter
(prelamination) Thickness 22. Cushion Density 6.3 lbs/ft.sup.3 23.
Release Layer Nonwoven felt construction: 24. Release Layer 70%
polyester/30% polypropylene blend composition 25. Release Layer 4
oz/yd.sup.2 weight: 26. Modular Shape: square or two-side double
chevron 27. Modular Size: 23'' square or nominal 23'' .times. 23''
28. Cutting Method: Controlled Depth cut from the back
Example 3
[0125] TABLE-US-00014 (A) (B) 1. Product Type Residential Modular
Floor Covering 2. Face: High Twist Frieze Cut pile 3. Primary
Backing: Woven polypropylene (PolyBac - 4 oz/yd.sup.2) 4. Total
Finished 28-55 oz/yd.sup.2 Yarn Weight: 5. Stitches Per Inch:
7.3-7.81 6. Tufting Gauge: 1/8 7. Yarn Polymer: Nylon 6,6 8. Yarn
Type: 1180 filament, with antistat, semi dull trilobal, 17 dpf 9.
Yarn Twist: 7.50 twist per inch in-singles (S) and ply (Z) 10. Yarn
Ply: 2 ply twisted 11. Heatset: Yes, @ 260 to 264.degree. F. with
steam frieze 12. Yarn Size: 3.69/2 cotton count 13. Tufted Pile
Height: 48/64 inches (3/4'') 14. Dyeing Method Jet Dye, Millitron
.RTM. jet dye machine 15. Precoat Adhesive: Styrene Butadiene
Latex, 12 oz/yd.sup.2 coating weight 16. Lamination Hotmelt with a
bitumen and polypropylene Tiecoat Adhesive: resin base, 17. Upper
Tiecoat 46 oz/yd.sup.2 Coating Weight: 18. Stabilizing Fiberglass
Mat, 2 oz/yd.sup.2, modified acrylic Reinforcement: binder 19.
Lower Tiecoat 15 oz/yd.sup.2 Coating Weight: 20. Cushion Type:
Rebond polyurethane foam, 7 millimeter uncompressed chip size 21.
Cushion 7 millimeter (prelamination) Thickness 22. Cushion Density
9 lbs/ft.sup.3 23. Cushion Weight 30 oz/yd.sup.2 24. Release Layer
Nonwoven felt construction: 25. Release Layer 70% polyester/30%
polypropylene blend composition 26. Release Layer 4 oz/yd.sup.2
weight: 27. Modular Shape: square or two-side double chevron 28.
Modular Size: 24'' square or nominal 24'' .times. 24'' 29. Cutting
Method: Controlled Depth cut from the back
Example 4
[0126] TABLE-US-00015 (A) (B) 1. Product Type: Residential Modular
Floor Covering 2. Face: High Twist Frieze Cut pile 3. Primary
Backing: Woven polypropylene (PolyBac - 4 oz/yd.sup.2) with a heavy
cap of low melt fibers calendared to bond the polypropylene
together 4. Total Finished 36 oz/yd.sup.2 Yarn Weight: 5. Stitches
Per Inch: 7.3 6. Tufting Gauge: 1/8 7. Yarn Polymer: Nylon 6,6 8.
Yarn Type: 1190 filament, with antistat, semi dull trilobal, 17 dpf
9. Yarn Twist: 7.50 twist per inch in singles (S) and ply (Z) 10.
Yarn Ply: 2 ply twisted 11. Heatset: Superba, @ 260 to 264.degree.
F. with steam frieze 12. Yarn Size: 3.69/2 cotton count 13. Tufted
Pile Height: 48/64 inches (3/4'') 14. Dyeing Method Jet Dye,
Millitron .RTM. jet dye machine, 20 gauge pattern 15. Precoat
Adhesive: Styrene Butadiene Latex, 12 oz/yd.sup.2 coating weight
16. Lamination Hotmelt with a bitumen and polypropylene Tiecoat
Adhesive: resin base, 17. Upper Tiecoat 46 oz/yd.sup.2 Coating
Weight: 18. Stabilizing Fiberglass Mat, 2 oz/yd.sup.2, modified
acrylic Reinforcement: binder 19. Lower Tiecoat 15 oz/yd.sup.2
Coating Weight: 20. Cushion Type: Rebond polyurethane foam, 15
millimeter uncompressed chip size 21. Cushion 7-8 millimeter
(prelamination) Thickness 22. Cushion Density 6 lbs/ft.sup.3 23.
Release Layer Nonwoven felt construction: 24. Release Layer 100%
polyester composition 25. Release Layer 2.5 oz/yd.sup.2 weight: 26.
Modular Shape: square or wave pattern 27. Modular Size: 18''-36''
28. Cutting Method: Controlled Depth cut from the back 29.
Preferred Install Without glue, Ashlar
Example 5
[0127] TABLE-US-00016 (A) (B) 1. Product Type: Residential Modular
Floor Covering 2. Face: High Twist Frieze Cut pile 3. Primary
Backing: Enhanced backing of woven polypropylene with needled and
calendered polyester and low melt polyester 4. Total Finished 39
oz/yd.sup.2 Yarn Weight: 5. Stitches Per Inch: 7.69 6. Tufting
Gauge: 1/8 7. Yarn Polymer: Nylon 6,6 8. Yarn Type: 1180 filament,
with antistat, semi dull trilobal, 17 dpf 9. Yarn Twist: 7.50 twist
per inch in singles (S) and ply (Z) 10. Yarn Ply: 2 ply twisted 11.
Heatset: Yes, @ 260 to 264.degree. F. with steam frieze 12. Yarn
Size: 3.69/2 cotton count 13. Tufted Pile Height: 48/64 inches
(3/4'') 14. Dyeing Method Jet Dye 15. Precoat Adhesive: Styrene
Butadiene Latex, 8 oz/yd.sup.2 coating weight 16. Lamination
Hotmelt with a bitumen and polypropylene Tiecoat Adhesive: resin
base, 17. Tiecoat Coating 46 oz/yd.sup.2 Weight: 18. Stabilizing
Fiberglass Mat, 2 oz/yd.sup.2, modified acrylic Reinforcement:
binder 19. Flame Lamination Fiberglass mat flame laminated to foam
20. Cushion Type: Rebond polyurethane foam, 15 millimeter
uncompressed chip size 21. Cushion 7-8 millimeter (prelamination)
Thickness 22. Cushion Density 6 lbs/ft.sup.3 23. Flame Lamination
Felt flame laminated to foam 24. Release Layer Nonwoven felt
construction: 25. Release Layer 70% polyester/30% polypropylene
blend composition 26. Release Layer 4 oz/yd.sup.2 weight: 27.
Modular Shape: 18'' square or nominal 23'' .times. 23'' two-side
double chevron 28. Modular Size: 18'' square or nominal 23''
.times. 23'' 29. Cutting Method: Controlled Depth cut from the
back
Comparative Examples 6-17
[0128] In the following comparative examples samples tested were as
follows: TABLE-US-00017 Sample Designation Material A Residential
carpet tile prototype built by Applicants with pinstripe surface
texturing tufted at 10.48 stitches per inch with a yarn weight of
38.39 ounces per square yard. The primary pile fabric is adjoined
to a high density prime urethane foam having a density of 16 lbs
per cubic foot by a layer of hot melt adhesive with a 2 ounce layer
of glass reinforcement material between the hot melt and the foam.
A felt backing is as described in Example 5 is disposed across the
underside of the foam. B A residential carpet tile prototype built
by Applicants with a construction identical to sample "A" but with
a standard cut pile face of off-white color. C Residential carpet
tile prototype built by Applicants having a cut pile tufted
construction of 8.68 stitches per inch with a yarn weight of 22.79
ounces per square yard and a deep golden speckled surface
coloration. The primary pile fabric was adjoined to an underlying
cushion with felt backing as in sample "A" including hot melt and
glass reinforcement. D A potentially preferred residential carpet
tile with rebond cushion corresponding substantially to the
specification is set forth in Example 5 above. E Commercially
available carpet tile sold under the trade designation GRAND PLAZA
by Milliken & Company. F Commercially available broadloom
carpet sold under the trade designation PATTERN MATES by Milliken
& Company and having a face weight of 38 ounces per square
yard. G Commercially available broadloom carpet sold under the
trade designation PATTERN MATES by Milliken & Company and
having a face weight of 55 ounces per square yard. H Broadloom
carpet having attached cushion of prime urethane and a scrim
backing marketed under the trade designation BUCKSKIN by Cherokee
Carpet Industries. I Carpet having a nylon cut pile face tufted at
9.33 stitches per inch at a pile height of 0.64 inches with a pile
weight of 36 ounces per square yard. This product is marketed under
style number SP120 by Mohawk Industries, Inc. J Carpet marketed by
Philadelphia Carpets under the trade designation CALM 12 having a
face weight of 30 ounces per square yard and a tufted pile height
of 0.375 inches. K Loop pilecarpet marketed by Mohawk Industries
under style number SP117 having a pile height of 0.160 inches with
5.0 stitches per inch and a certified pile weight of 26.00 ounces.
L Loop pile carpet product marketed under the trade designation
ROAD RUNNER by Milliken & Company M Bonded carpet product
marketed under the trade designation WHITE WATER by Milliken &
Company. N Carpet tile having a textured loop surface and a felted
backing. O Bonded pile surface carpet tile having a pile height of
0.245 inches and finished pile weight of 28 ounces per square yard
marketed under the trade designation COLOR ACCENTS by Milliken
& Company.
Comparative Example 6
[0129] The compression of the face only for various samples was
tested using ASTM specification D3574 Test C (Compression Force
Deflection Test) modified to measure 60% compression at reading.
The results are tabulated below. TABLE-US-00018 Compression modulus
Sample (psi) I 12.802 A 87.968 B 125.267 J 148.987 G 190.794 L
251.773 H 326.901 E 354.99 F 500.864 C 608.977 K 753.888 M 1063.683
O 1149.635
Comparative Example 7
[0130] The procedure of Example 6 was repeated in all respects
except that the compression modulus was to the entire sample
composite. TABLE-US-00019 Compression modulus Sample (psi) D
261.408 H 280.936 A 285.452 B 368.239 L 602.084 C 777.584 N
1066.748 O 1146.429 E 1515.57 M 2121.788
Comparative Example 8
[0131] The procedure of Example 6 was repeated except that force
was measured at 50% compression. The tested portion of the sample
consisted only of the foam pad, fiberglass reinforcing layer and
hot melt tie-coat layer. TABLE-US-00020 Compression modulus Sample
(psi) D 23.444 B 32.672 C 33.635 A 36.252 E 72.074 N 73.987
Comparative Example 9
[0132] The procedures of Example 6 were repeated in all respects
except that force was measured at 50% compression. TABLE-US-00021
Sample Compression modulus (psi) Cushion only from sample "D"
13.389 4 lb rebond foam underlay from 11.285 Mohawk Industries 6 lb
rebond foam underlay from 12.405 Mohawk Industries 8 lb rebond foam
underlay from 51.052 Mohawk Industries
Comparative Example 10
[0133] Compression recovery was measured for various samples. A
constant force of 200 pounds was applied to the test specimen. Two
complete cycles of loading and relief were applied and the load
modulus for each cycle was recorded. The average percentage change
of the sample between the first cycle and the second cycle is
reported based on the following formula. ( Height .times. .times.
at .times. .times. valley - Height .times. .times. at .times.
.times. peak ) .times. .times. second .times. .times. cycle (
Height .times. .times. at .times. .times. valley - Height .times.
.times. at .times. .times. peak ) .times. .times. first .times.
.times. cycle ##EQU2## TABLE-US-00022 Sample Recovery % D 63.5 C
68.2 H 70.1 B 72.3 A 72.4 E 80.5 O 81.7
Comparative Example 11
[0134] Planar dimensional stability of various samples was tested
by loading a two inch wide strip in a tensile tester and measuring
percent elongation. TABLE-US-00023 % elongation Sample (100 lbs
force) D 5.6 H 13.9 O 2.4
Comparative Example 12
[0135] This example procedure provides for a measurement of
resistance to deformations that would cause a carpet tile to go
from square to trapezoidal, for instance, due to a shear force on
one side of the carpet. The measurement data were collected using a
Sintech 1/s mechanical tester controlled by MTS's Testworks 4
software. As the sample is subjected to a shearing force, the force
required to shear versus displacement of one end of the sample is
measured. More specifically, [0136] 1. The setup includes two
hydraulic jaws with a gap of 2.5 inches between then laterally. One
jaw is fixed and the other is attached to the movable head of the
Sintech mechanical tester. A 500-pound load cell was used on the
movable head. [0137] 2.2.times.8 inch strips of carpet are cut
using a die. The carpet sample is loaded with the long direction
horizontal. The gap between the hydraulic jaws is 2.5 inches so
that 5.5 inches of the carpet sample is firmly held (symmetrically)
by the two hydraulic jaws on either side of the sample. [0138] 3.
The two hydraulic jaws are originally set at the same height (with
a gap of 2.5 inches laterally between them). The movable jaw cycles
from the same height as the fixed jaw through a displacement of 0.5
inch, first higher than the stationary jaw, and then lower than the
stationary jaw, and then returns to its starting point. This
defines a single cycle of deformation. [0139] 4. As the shear
deformation cycle progresses, the force versus displacement cycle
is recorded. The data shows a hysteretic behavior. [0140] 5. To
measure the initial shear modulus of the carpet, the slope of the
shear force versus shear displacement is calculated for the data
from 0-0.08 inch displacement. The resulting initial modulus data
are not normalized by the dimensions of the sample. [0141] 6. To
calculate the Energy (or work) dissipated during the deformation
cycle, the area between the forward and reverse shear deformation
curves (the curves are hysteretic) is calculated. The resulting
energy dissipated data are not normalized by the dimensions of the
sample.
[0142] The results are set forth in the following table.
TABLE-US-00024 Initial modulus Energy Sample (lbF/in) (lbF * in) H
9.73 1.39 D 181.02 15.55 E 294.73 20.35
Comparative Example 13
[0143] The ability of various samples to abut across a flooring
surface without seam visibility was evaluated as a function of a
developed index referred to as Seamability Index.
[0144] The Seamability Index is defined by the mathematic
visibility of the seam in a digital image of the seam. The RGB
digital images were captured using a Javelin Electronics Chromachip
II model JE3462RGB camera in manual mode. The lighting used was
fluorescent room lights. Illumination was set through the iris on
the lens. The RGB histogram of the image was checked in Adobe
Photoshop 6.0 to make sure none of the pixels were clipped at 0 or
255 (8 bit data storage). The camera was placed 33 inches above the
sample and captured 480.times.640 pixel resolution images that
spanned roughly 8.5.times.11.5 inches. The carpet seam was aligned
within the image to go parallel to one of the edges of the image so
that line averaging could be done across the whole image in one
direction. For seams that are not linear, Adobe Photoshop 6.0 was
used to piecemeal cut the image and paste the seams together in a
line. The seam shape can be marked within the image by placing a
marker in the shape of the seam parallel to the seam.
[0145] To prepare the images, two identical tiles were used. The
two tiles were seamed in every possible configuration with the tile
tufting direction oriented in the same direction. To put the seam
in a known configuration, the seam was brushed perpendicularly to
the seam with a light hand brushing in a single direction.
[0146] The seam is made difficult to identify because of the hiding
action of overhanging tufts, printed patterns, three dimensional
texturing, etc. To quantify a seam, the deviations due to the seam
in the image from the average color value of the base carpet must
be quantified. Because there are variations in the image of the
carpet that occur regardless of a seam simply due to the bright and
shadow points of the tufts (or loops) in the carpet, or other
patterns, printing, etc., there are at least two types of
variability in the image of a carpet seam. The standard deviation
of the color differences from the average color value in the
absence of a seam is used to characterize the variability intrinsic
to the carpet (in the absence of a seam).
[0147] Because the tufts, loops, printing, or physical texture of
the carpet causes very rapid changes in the digital image's pixel
values within a small neighborhood, data averaging is utilized to
obtain data with a large signal (seam) to noise (base carpet
variability) value. The Seamability calculation is based on data
averaged over 8 inches in a single direction along a line parallel
to the seam. This analysis is generally applicable to carpet
substrates where the carpet base is one color or where the texture
or printing has the tendency to average to a uniform background
over the 8 inch sampling interval used in this test protocol.
[0148] The RGB image files are converted to Adobe Lab space within
Adobe Photoshop 6.0. The L, a, and b pixel intensity data are each
individually averaged in the image in a direction parallel to the
seam for a distance of 8 inches to create a line profile of the
average intensity in each channel. This brings out the seam
information relative to the texture. From this line profile, the
average value of L, a, and b for the carpet can be calculated by
averaging along the line profile all of the pixel values (except at
the seam). The deviation from the average value along the line can
be calculated so that one has (L-L.sub.avg), (a-a.sub.avg), and
(b-b.sub.avg) line data. The (L-L.sub.avg), (a-a.sub.avg), and
(b-b.sub.avg) line data are then combined using a color difference
formula: ?E (color
difference)=((L-L.sub.avg).sup.2+(a-a.sub.avg).sup.2+(b-b.sub.avg).sup.2)-
.sup.1/2.
[0149] The standard deviation of the delta E of the carpet texture,
(sigma) is next calculated from the delta E line spectra (except in
the region of the line that reflects the seam. Then, the point
along the delta E line with the maximum deviation (delta E) from
the average is found. The value of delta E is recorded. Then the
ratio of the maximum deviation (delta E) to the standard deviation
(sigma) is calculated as a measure of whether a seam is present or
not. The value delta E/sigma also gives a numeric quality measure
to the seam. Because of the way that a standard deviation is
defined, a Seamability index of 3 or less is probably just the base
carpet (95% chance). This would mean that there is no seam present.
A large Seamability Index indicates that there is probably a seam
present. The larger the Index is, the more noticeable the seam is.
The data analysis was performed in image Pro Plus 4.5. The data was
averaged in a line using a standard line-averaging tool. The
standard deviation (sigma) and maximum deviation (delta E) were
calculated from the line profile using macros written in-house
using Image Pro Plus macro language.
[0150] The results are tabulated in the following table.
TABLE-US-00025 Average Seam Sample Index Seam 1 Seam 2 Seam 3 Seam
4 A 3.50 3.06 4.87 3.04 3.02 B 7.36 4.13 12.78 5.72 6.82 C 6.74
4.45 8.36 3.52 10.64 D (Dark 2.95 3.02 2.82 3.33 2.62 Green) D
(Beige) 3.92 4.84 4.12 3.16 3.56 D (Light 2.70 3.10 2.37 2.40 2.93
Blue) N 3.98 2.30 5.64 2.36 O 6.72 8.52 2.96 7.75 7.65
Comparative Example 14
[0151] A measurement of relative tuft overlay along the perimeter
of various samples was conducted.
[0152] For purposes of this example, "Tuft Overlay" is defined as
the area produced by tufted yarns exceeding an invisible plane
created by the outer edges, perpendicular to the carpet tile
backing, enabling the measurability through electronic image
capture and computer image analysis.
Sample Prep:
[0153] 1. Brush the tufted face with an 8-inch medium bristled
brush applying moderate pressure perpendicular to the perimeter
edge as to maximize tuft overlay. Image Capture: [0154] 2. Place
carpet tile (tufted face up) onto the glass scanner bed utilizing
the full length of scanning surface. [0155] 3. Use Umax's Magic
Scan software using default settings to capture scanned images.
[0156] 4. All samples are scanned using 200 dpi and saved as True
Color RGB tif images [0157] 5. Use Adobe Photoshop version 6.0
Software to convert images to Lab color space and to split an image
into three images each representing one axis in Lab color space.
[0158] 6. The three newly saved images a then opened using Image
Pro Plus version 4.5 image analysis software. [0159] 7. The images
are rotated as to display the edge horizontally on the monitor.
[0160] 8. The color channel image with the most pixel image data in
relation to the area of interest (the tuft overlay region) is then
threshold automatically based on detected area size maximum and
minimum parameters and gray level values. [0161] 9. The detected
isolated area is then measured to determine area size and then
divided by the width (longest aspect of image--represents carpet
tile edge length), resulting in the average tuft overlay distance
in millimeters along the length of the scanned carpet tile
edge.
[0162] The results for each of four sides of a representative
carpet tile are set forth in the following table. TABLE-US-00026
Tuft Overlay Avg Overhang Avg Overhang Sample # Side along side
(mm) per Tile (mm) D 1* 9.48 2 2.49 3 6.10 4 3.28 5.34 A 1* 2.11 2
4.57 3 0.45 4 5.14 3.07 B 1* 0.08 2 3.21 3 3.05 4 4.19 2.63 C 1*
0.00 2 0.58 3 0.70 4 0.31 0.40 N 1* 0.40 2 0.23 3 0.14 4 0.65 0.35
E 1* 2.39 2 4.53 3 4.62 4 5.51 4.26
Comparative Example 15
[0163] As procedure was developed to assess the quality (the
straightness of the cut through the carpet composite) as well as
the "true-ness" of the shape of the cut on a side. [0164] 1.
Samples are prepared by using a die cutter to cut representative
pieces from a carpet square on the seams of interest. Note that the
seam to be assessed (the commercially cut edge) is not touched by
the die, unless a die cut seam is the desired joint. [0165] 2.
Along the seam joint of interest, the tuft yarns are shaved off of
the face of the carpet to insure that they do not interfere with
the measurement. These yarns are shaved off to a distance of at
least 1/2 inch from the carpet edge of interest. [0166] 3. Two
carpet tile edges are placed face down on a light box (we used The
Back Light, Model HPE1218, by Hall Productions) so that the light
box will illuminate the seam formed by the tile edge of interest.
Any places along the seam where the edges of the tile do not come
into direct contact will allow light to transmit through the joint.
[0167] 4. The seam with the light box backlight is imaged with a
CCD camera. We used a Javelin Electronics Chromachip II model
JE3462RGB camera in manual mode. The illumination levels of the
digital image were set using the iris on the camera lens. The RGB
histogram of the image was checked in Adobe Photoshop 6.0 to make
sure none of the pixels were clipped at 0 or 255 (8 bit data
storage). The data was converted to Adobe Lab color model. The
light passing through the seams was adjusted so that its Adobe L
value was as close to 255 without clipping the signal. The camera
was placed 28 inches above the sample and captured 480.times.640
pixel resolution. [0168] 5. To insure correct spatial calibration,
a ruler was imaged in the horizontal and vertical directions of the
image. This allows a correspondence between pixel values and
length. [0169] 6. To insure good digital contrast between the light
exiting the seam and the backing of the carpet tile, black
construction paper (in the shape of the seam) was placed over the
back of the carpet tile (average digital count value of 70 and all
values <128) in such a way to cover as much of the carpet
backing as possible without clipping the light transmitting through
the seam. [0170] 7. The two pieces of carpet tile are compressed
together by hand with light force and then slowly released. [0171]
8. An image is captured of the resulting seam, converted to Adobe
Lab color model and split into it separate L, a, and b images. The
L image alone was used for the assessment. [0172] 9. Image Pro Plus
4.5 was used to count the number of pixels with digital count
greater than 128 (representing transmitting intensity through the
seam). This actually is an area calculation but it directly
correlates to number of pixels. The software was also used to
measure the length of the seam. [0173] 10. Using the area of light
pixels (areas where there is not good contact between seams) and
the length of the seam imaged, the average width of non-contact per
seam length is calculated. The results of this assessment are
presented graphically in FIG. 27.
Comparative Example 16
[0174] In order to evaluate the relative bulk of the pile face on
various samples the normal pile layer height was measured from the
primary backing to the top of the pile yarns. The average fully
extended yarn length from the primary backing was also measured. A
Bulk Index was then calculated as the ratio of the extended yarn
length to the normal pile height. The standard pile density was
then calculated using the following formula. m/p where: [0175]
m=calculated mass of yarn above primary backing in one square yard
based upon shaving representative areas; and [0176] p=height of
pile in yards
[0177] The results of the analysis for various samples are set
forth in the following table. TABLE-US-00027 Pile Bulk Character
Standard Ratio of Pile Density Extended extended based on Pile
layer Yarn length yarn pile layer height under above length height
under normal primary divided by normal conditions backing pile
layer conditions Sample (inches) (inches) height (oz/cubic yd) A
0.386 0.43 1.11 2607 B 0.426 0.45 1.06 2547 C 0.256 0.275 1.07 1799
D 0.418 0.6 1.44 2504 E 0.28 0.3 1.07 4357 F 0.433 0.6 1.39 2354 G
0.543 0.63 1.16 2749 H 0.276 .6* 2.17 2311 I 0.539 0.55 1.02 2025**
J 0.304 0.34 1.12 2919** K 0.181 0.41* 2.27 5850** L 0.173 0.32*
1.85 2091 M 0.165 0.18 1.09 1455 N 0.15 0.28* 1.87 1908 O 0.177
0.19 1.07 6893 *Loop cut and measured **Value reported by
manufacturer based on certified pile weight
Comparative Example 17
[0178] Two tiles of each sample were cut about 6'' wide and 10''
long, leaving one 6'' edge from the outside edge of the original
tile unmodified. Two unmodified edges were placed together to form
a seam and held in place. A MTS Sintech 1/S materials testing
system with a 5.62 lb. load cell was used to pull a Long Tooth
Undercoat Rake Just for Dogs across the seam at 3.94 inches/minute.
The rake weighs 3.1 ounces and has 20 teeth 11/16'' long evenly
spaced along a 37/8'' length. The rake was pulled across the seam
such that the row of teeth was parallel to the seam for a total
length of six inches. The force needed to maintain the constant
speed was recorded and plotted as a function of position, where the
initial position is the zero point. The Testworks 4 software
package was used to collect the data, and three data sets were
averaged for each sample.
[0179] The data were analyzed using Igor. The first inch of the
scans was disregarded, since that portion of the data indicates the
force needed to set the rake in motion initially. The global
maximum value of the force function was found, and then the local
minimum just before the maximum was identified. The difference
between these two force values is called the "amplitude". The
"amplitude" was then divided by the standard deviation of the force
function between the 1'' and 6'' values. This quotient is called
the "seam strength".
[0180] The results are set forth in the following table and
demonstrate a superior seam in the exemplary product.
TABLE-US-00028 Samples Amplitude Stddev Strength E 92.2 13.4 6.8806
D 55.2 25.4 2.17323 C 135.7 23 5.9 A 136.3 24.1 5.6556 B 96.4 21.5
4.48372 O 13.44 8 1.68 N 90.4 14.4 6.27778
[0181] While the modular products of the present invention are not
limited to carpet tiles for residential use, it is in accordance
with at least one embodiment of the present invention that carpet
tiles have special applicability to the residential market and, in
particular, in the living room and bed rooms of homes as a
replacement for broadloom carpet over broadloom pad. In this
particular embodiment, it is preferred that the carpet tiles
provide a carpet tile installation which substantially looks and
feels like broadloom carpet over pad.
[0182] Also, in accordance with at least one embodiment of the
present invention, the carpet product or construction of the
present invention may be in the form of tiles, runners, mats,
sheets, area rugs, roll product, and the like. For example,
18''.times.18'' tiles, 24''.times.24'' tiles, 36''.times.36''
tiles, 4'.times.6' sheets, 4'.times.8' sheets, 4'.times.12' sheets,
2'.times.20' rolls, 3'.times.20' rolls, 4'.times.20' rolls,
6'.times.20' rolls, and the like.
[0183] In accordance with at least one embodiment, the modular
product of the present invention is preferably flexible enough to
be used on stairs, around corners, and the like. For example,
2'.times.20' stair runners that match with the 23''.times.23''
carpet tiles.
[0184] In accordance with yet another embodiment, a system or line
or products is provided including carpet tiles, carpet sheets,
carpet rolls, and the like which have piles, yarns, patterns,
designs, or colors which match or coordinate with other broadloom
carpet products, so that one can select matching or coordinating
flooring from a full line of carpet type flooring products.
Commonly owned U.S. Patent Applications, Docket No. 5113G, Ser. No.
10/198,238, filed Jul. 18, 2002, entitled "Residential Carpet
Product and Method" and Ser. No. 10/154,187, filed May 23, 2002,
are each hereby incorporated by reference herein, and international
application no. PCT/US02/22854, filed Jul. 18, 2002, is hereby
incorporated by reference herein.
[0185] It is to be understood that while the present invention has
been illustrated and described in relation to potentially preferred
embodiments, constructions and practices, that such embodiments,
constructions and practices are intended to be illustrative only
and that the invention is in no event to be limited thereto.
Rather, it is contemplated that modifications and variations
embodying the principles of the present invention will no doubt
occur to those of skill in the art and it is therefore contemplated
and intended that the present invention will extend to all such
modifications and variations as may incorporate the broad
principles of the present invention.
* * * * *