U.S. patent application number 14/421833 was filed with the patent office on 2015-08-20 for tackless carpet strip.
The applicant listed for this patent is Glen P. GREATHOUSE, Brian McKENNA, Michael H. McKENNA. Invention is credited to Glen P. Greathouse, Brian McKenna, Michael H. McKenna.
Application Number | 20150230646 14/421833 |
Document ID | / |
Family ID | 50099006 |
Filed Date | 2015-08-20 |
United States Patent
Application |
20150230646 |
Kind Code |
A1 |
Greathouse; Glen P. ; et
al. |
August 20, 2015 |
TACKLESS CARPET STRIP
Abstract
A tackless carpet strip for affixing carnet to a hard surface
has a flat base with spikes extending from the base at an angle. A
lower surface of the base is coated with protective sealant. A foam
adhesive tape strip has two adhesive surfaces; the first surface is
permanently adhered to the lower surface of the base. The second
adhesive surface is covered with a removable protective film.
Inventors: |
Greathouse; Glen P.;
(Andalusia, AL) ; McKenna; Michael H.; (Andalusia,
AL) ; McKenna; Brian; (Andalusia, AL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
GREATHOUSE; Glen P.
McKENNA; Michael H.
McKENNA; Brian |
|
|
US
US
US |
|
|
Family ID: |
50099006 |
Appl. No.: |
14/421833 |
Filed: |
August 16, 2013 |
PCT Filed: |
August 16, 2013 |
PCT NO: |
PCT/US13/55386 |
371 Date: |
February 15, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61683974 |
Aug 16, 2012 |
|
|
|
Current U.S.
Class: |
16/16 ; 156/256;
156/289 |
Current CPC
Class: |
Y10T 156/1062 20150115;
A47G 27/0462 20130101; F16B 5/07 20130101; Y10T 16/131 20150115;
F16B 5/12 20130101; Y10T 156/10 20150115; A47G 27/045 20130101 |
International
Class: |
A47G 27/04 20060101
A47G027/04; F16B 5/12 20060101 F16B005/12; F16B 5/07 20060101
F16B005/07 |
Claims
1. A carpet strip, comprising: a flat base; a plurality of spikes
extending through a lower surface of the base and protruding
therefrom at an angle; a resilient adhesive tape strip comprising
two adhesive surfaces, the first adhesive surface permanently
adhered to the lower surface of the base, the second adhesive
surface covered with a removable protective film.
2. The carpet strip of claim 1, wherein the base is formed from
wood.
3. The carpet strip of claim 1, wherein the base is formed from
composite material.
4. The carpet strip of claim 1, wherein the base is formed from
plastic.
5. The carpet strip of claim 1, wherein the base is formed from
metal.
6. A process for manufacturing a carpet strip comprising the steps
of: forming a thin base of material comprising an upper surface and
a lower surface; installing spikes in the lower surface of the base
such that the spikes extend through the base and protrude therefrom
at an angle; adhering double-sided adhesive tape to the lower
surface of the base, the tape comprising a first and a second
adhesive surface, the first adhesive surface adhered to the lower
surface of the base, the second adhesive surface covered with a
removable protective film; compressing the base and tape together
to affix the tape to the base.
7. The carpet strip of claim 6, wherein the forming the base of
thin material step comprises forming the material into a strip.
8. The carpet strip of claim 6, further comprising the step of
cutting the base into a plurality of individual strips.
9. The carpet strip of claim 6, wherein the first and second
adhesive surfaces comprise rubber adhesive.
10. The carpet strip of claim 6, wherein the double-sided adhesive
tape comprises closed cell crosslinked polyethylene foam.
11. The carpet strip of claim 10, wherein the tape is at least 1/32
inches thick.
12-17. (canceled)
18. The carpet strip of claim 6, further comprising the step of
sealing the lower surface of the base with a protective
sealant.
19. The carpet strip of claim 1, wherein the lower surface is
coated with a protective sealant.
20. The carpet strip of claim 1, wherein the resilient adhesive
tape strip comprises closed cell crosslinked polyethylene foam.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Application No. 61/683,174 titled "Tackless Carpet Stripping,"
filed on Aug. 16, 2012, the entire contents of which are
incorporated herein by reference.
BACKGROUND AND SUMMARY OF THE INVENTION
[0002] Traditional carpet tack strips for attaching carpet to a
floor in a room are composed of strips of wood or other material
that are nailed to the floor around the edges of a room. A typical
carpet tack strip is approximately four feet in length, about an
inch wide and about a quarter of an inch in thickness, with the
bottom surface of the strip positioned en the floor and fastened to
the floor with a plurality of nails driven through the strip and
into the floor. A four-foot strip typically requires nine nails to
secure the strip to the floor.
[0003] The upper surface of the carpet tack strip comprises a
plurality of sharp-edged spikes that extend upwardly from the upper
surface of the strip and project above it at an angle inclined with
respect to the upper surface of the strip such that the spikes
project toward an adjacent wall When installed. The carpet is
secured to the spikes on one wall and stretched across and secured
to the spikes on remaining walls.
[0004] A disadvantage of traditional carpet strips is the need for
nails (tacks) to secure the strips into the floor. When floor is
made of concrete, for example, installing the strips may present
difficulties, however, because driving, concrete nails into old
concrete is sometimes impossible. Further, certain types of
concrete flooring (e.g., Terrazzo) are so hard that they will not
accept concrete nails, and the carpet installer mug drill into it
in order to affix strips.
[0005] One option for fastening carpet strips to concrete floors is
to use an adhesive such as Chemrex.RTM. brand adhesive. The
adhesive is applied to the strip and the strip is pressed onto the
floor. While adhesive provides a good strong bond between the strip
and the floor, the cure time--for some adhesives the time between
adhesion of the strip to the floor and when the strip is ready bar
the carpet to be stretched--is at least two hours, and possibly
more.
[0006] More recently, hot glue guns have been used to apply carpet
strips to floors. However, these devices must he plugged into an
electrical source, and also require some cure time.
[0007] The carpet strips of the present disclosure provide an
advantage over the previous methods for attaching carpet strips to
flooring, in that no nails or other fasteners are required to be
driven into the floor. This is because the strips are affixed to
the flooring using peel-and-stick tape that is adhered to the
carpet strip and to the floor. Further, no cure time is required,
and the carpet may be stretched immediately after the carpet strips
are affixed to the floor.
[0008] For purposes of summarizing the invention, certain aspects,
advantages, and novel features of the invention have been described
herein. It is to be understood that not necessarily all such
advantages may be achieved in accordance with any one particular
embodiment of the invention. Thus, the invention may be embodied or
carried out in a manner that achieves or optimizes one advantage or
group of advantages as taught herein without necessarily achieving
other advantages as may be taught or suggested herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The disclosure can be better understood with reference to
the following drawings. The elements of the drawings are not
necessarily to scale, emphasis instead being placed upon clearly
illustrating the principles of the disclosure. Furthermore, like
reference numerals designate corresponding palls throughout the
several views.
[0010] FIG. 1 is a perspective view of a prior art carpet
strip.
[0011] FIG. 2 is a perspective view of a carpet strip according to
an embodiment of the present disclosure.
[0012] FIG. 3 is a side plan view of the carpet strip of FIG. 2,
shown installed on a floor, before the carpet is installed.
[0013] FIG. 4 is a side plan view of the carpet strip of FIG. 3,
with the carpet installed.
[0014] FIG. 5 depicts a method of installing carpet strips
according to an embodiment of the present disclosure.
[0015] FIG. 6 depicts a method of manufacturing a tackless carpet
strip according to an embodiment of the present disclosure.
[0016] FIG. 7 depicts an end view of a strip base before spikes are
installed into the base.
[0017] FIG. 8 depicts an end view of the strip base of FIG. 7 with
spikes installed.
[0018] FIG. 9 depicts and end vide of the strip base of FIG. 7 with
tape installed.
[0019] FIG. 10 depicts an embodiment of manufacture of the strips
according to the present disclosure.
[0020] FIG. 11 is an enlarged end view of the carpet strip of FIG.
9, shown installed on a floor
[0021] FIG. 12 is an enlarged detail view of the carpet strip of
FIG. 11, taken along detail view "A" of FIG. 11.
DETAILED DESCRIPTION
[0022] FIG. 1 is a perspective view of a prior art carpet tack
strip 10. The strip 10 comprises a strip base 1 that is formed from
wood or other suitable material. The strip 10 has a top surface 4
from which a plurality of spikes 3 protrude upwardly at an angle. A
plurality of tacks or nails 2 extend through the strip base 1 and
are driveable into a floor (not shown) to secure the strip 10 to
the floor. The spikes 3 angle toward a wall (not shown) against,
which the strip 10 is installed, and the spikes 3 anchor a carpet
(not shown) that is installed on the floor and stretched from strip
to strip.
[0023] FIG. 2 is a perspective view off the tackless carpet strip
20 according to an embodiment of the present disclosure. The strip
20 comprises a strip base 11, which is formed from wood or other
suitable material, such as plastic or aluminum. The strip 20 has a
top surface 14 from Which a plurality of spikes 13 protrude
upwardly at an angle. No nails 2 (FIG. 1) are required to secure
the strip 20 to the floor (not shown). Instead, tape 22 affixed to
a lower surface 24 of the strip 20 adheres to the floor, as farther
discussed herein.
[0024] The strip 20 has a width "Ws" of around three-quarters of an
inch (3/4'') to one inch wide in the illustrated embodiment. For
some specialized applications in other embodiments, the strip 20
may be two (2) inches wide, for example. The tape 22 has a width
"Wt" that is generally somewhat less than the width Ws of the strip
20. The tape 22 and the strip 20 are generally the same length,
i.e., the tape 22 extends for the full length of the strip 20.
[0025] FIG. 3 is a side view of the tackless carpet strip 20
installed on a floor 25 prior to installation of the carnet (not
shown). The strip 20 is installed adjacent to but not directly
contacting, a wall 23. The spikes 13 extend upwardly from the top
surface 14 of the strip 20 and angle toward the wall 23. Tape 22 is
affixed to the lower surface 24 of the strip 20. In some
embodiments, the tape 22 comprises polyethylene foam double-sided
tape that is "pre-installed" on the strip 20 by a manufacturer,
such that a user simply has to remove a protective covering (not
shown) that covers the tape 22 on the lower side of the strip 20,
before installing the strip 20 on the floor 25. In other
embodiments, the user (not shown) installs the tape 22 to the strip
20 before installing the strip 20 to the floor 25.
[0026] In one embodiment, the tape 22 has a thickness of generally
1/32 inches, though tapes that are thicker could also be used. An
important feature of the tape 22 is that it have sufficient
thickness and resiliency to adhere well to irregular surfaces,
because when installing carpet over concrete slabs, for example,
the slab surface is not perfectly flat. Closed cell crosslinked
polyethylene foam tape with a minimum thickness of about 1/32
inches and up to about 1/16 inches demonstrated the desired
resiliency in tests performed. The tape 22 comprises adhesive on
its top and bottom surfaces, and rubber adhesive is used in some
embodiments.
[0027] FIG. 4 is a side view of the tackless carpet strip 20 of
FIG. 3, after installation of a carpet 26. The carpet 26 is
stretched across the floor 25 on top of a carpet pad 27. The carpet
26 is retained at its end 28 near the wall 23 by the spikes 13
(FIG. 3) which extend through the carpet 26 and secure the carpet
26 to the strip 20. The tape 22 is strong enough to maintain the
strip 20 secured to the floor 25 even with the force of the carpet
26 acting on the strip 20,
[0028] FIG. 5 illustrates the method 100 of installing, the
tackless carpet strip 20 (FIG. 3) to the floor 25 (FIG. 3). This
method 100 presumes that the user has procured a strip 20 with
spikes 12 already driven through it (e.g., a commercially available
carpet strip, but without the nails).
[0029] In step 101 of the method 100, the user (not shown) prepares
the lower surface 24 (FIG. 3) of the strip 20 to receive the tape
22. In order to achieve good adhesion of the tape 22 to the strip
20, the lower surface is sealed. In this regard, because the base
11 is typically formed from unsealed wood (e.g., plywood), a
sealant is used to seal the pores of the wood and prevent the wood
from drying out the adhesive in the tape and compromising the
adherence of the strip 20 to the tape 22. Any of a number of
sealants may be used for this purpose, and in one embodiment a
clear lacquer sealant was employed. Primer paint or other sealants
could be used, in the alternative.
[0030] After the sealant has dried, in step 102, the user adheres a
first (top) adhesive side of the tape 22 to the strip 20 (not
shown) from the first adhesive side of the tape 22 and pressing the
first adhesive side of the tape 22 to the strip 20.
[0031] Steps 101 and 102 may be desired to be performed at it
manufacturer's site, such that the strips 20 are shipped to the
user with the tape 22 pre-installed on the strips, as trainer
discussed herein.
[0032] In step 103, the user prepares the strip 20 for installation
onto the floor 25 by cutting it to the desired length and removing
the protective backing from a second (bottom) adhesive side of the
tape 22. In step 104, the user affixes the strip 20 to the floor 25
by pressing it to the floor 25 in the desired location, adjacent to
the wall 23. Pressing the strip 20 to the floor 25 causes the
adhesive sides of the tapes to adhere to the floor 25 and the strip
20.
[0033] The floor 25 should he generally clean and as free as
possible of dust before adhering the strip 20, in order to get the
hest possible adherence of the strip 20 to the floor 25. In some
instances, the user may want to prepare the floor 25 for receiving
the strip 20 by applying a solution of diluted liquid latex. In one
example, the user applied a 5-1 solution of liquid latex and water
by sprinkling the solution onto the floor 25 and wiping it with a
cloth.
[0034] In step 105 of the method, the user installs the carpet 26
(FIG. 4) onto the floor 25 via the methods known in the art,
securing the carpet 26 to the strip 20. No cure time is required
between the installation of the strip 20 onto the floor 25 and the
installation of the carpet 26, therefore the carpet 26 may be
immediately installed.
[0035] In another embodiment of the disclosure, instead of a
double-sided tape adhering the strip 20 to the floor 25, a
pressure-sensitive adhesive (not shown) is employed. A rubber
adhesive is used in one embodiment. This adhesive may be coated
(i.e., painted) onto the lower surface 24 of the strip 20 and then
the exposed lower surface is covered with a protective covering,
such as wax paper or other suitable material. When the user is
ready to install the strip 20, he removes the protective covering
and adheres the strip to the floor as discussed above.
[0036] FIG. 6 illustrates a method 200 of fabricating the tackless
carpet strip 20 (FIG. 3). This method 200 generally presumes that
the tape 22 is installed on to the carpet strip 20 at the
manufacturer's location. In step 201 of the method 200, the strip
base 11 is formed from a sheet (not shown) of material. Wood (e.g.,
plywood) is traditionally used for the strip base 11, though other
materials, such as plastic or composite materials, could be
used.
[0037] FIG. 7 depicts an end view of the strip base 11. The strip
base 11 has a lower surface 24 that is generally flat and generally
smooth. The lower surface 24 is prepared for adhesion of tape by
sanding of the lower surface 24, followed by application of a seal
primer. Any suitable primer for sealing surfaces of the type the
strip base 11 is formed from (e.g., wood) may be used to prime the
lower surface 24.
[0038] As discussed above, the strip base 11 is generally between
3/4'' and 1'' wide, because the finished strip 20 is desired to be
this width. (Wider strips are used for some commercial carpet
applications.) Although the illustrations show such generally
narrow strips, in some embodiments, the strip 20 may be formed in
large sheets before being cut into strips of this width. For
example, in one embodiment, a large sheet of wood has spikes and
tape applied before being cut into snips 20.
[0039] In step 202 of the method of FIG. 6, the spikes 13 are
driven through the strip base 11. FIG. 8 depicts an end view of the
strip base of step 202. A machine that is known in the art (not
shown) may be used to drive multiple spikes 13 through the lower
surface 24 at an angle, such that the tips 16 of the spikes 13
extend through the base 11 angularly, and the heads 15 of the
spikes 13 are generally recessed into the lower surface 24.
[0040] Note that the preparation of the lower surface 24 by sanding
and sealing may be delayed until after step 202 in other
embodiments of the method 200.
[0041] In step 203, illustrated in FIG. 9, the tape 22 is installed
on the lower surface 24, over the spikes 13. i.e., the tape 22
generally covers the heads 15 of the spikes completely. The lower
surface 17 of the tape 22 comprises a non-adhesive strip (not
shown) that prevents the lower surface 17 of the tape 22 from
sticking to surfaces until the non-adhesive strip is removed.
Application of the tape 22 to the strip may be done by rolling the
tape 22 onto the base 11. In this regard, the tape 22 may be
supplied in large rolls (not shown), which may be unrolled onto the
base 11.
[0042] In one embodiment, the tape 22 is not supplied in rolls and
unrolled onto the base. Rather, the polyethylene foam that the tape
22 is formed from is sprayed onto the lower surface 24 and covered
with it non-adhesive strip, e.g., wax paper. Before the foam is
applied to the lower surface 24, a liquid adhesive is applied. Then
after the foam is applied, a second layer of liquid adhesive is
applied, to which the non-adhesive strip is releasably affixed. The
foam (not shown) should he sufficiently thick to provide the
desired resiliency, as discussed above. Foam thicknesses of 1/32
inch to 1/16 inch have been employed, and thicker foam layers are
also possible.
[0043] In step 204, the base 11 and tape 22 are compressed to cause
the tape 22 to adhere securely to the base 11 and form the strip
20. This compression step 204 is desirable to help remove air that
may be between the tape 22 and the base 11. The step 204 may be
performed using one of a number of methods. For example, the strip
20 could be laid upon a non continuous surface (e.g., a grid or
strips of supporting material) with the spikes oriented downward
such that the spikes 13 extend through openings. And then a roller
could be rolled over the tape 22 to compress the tape 22 to the
base 11.
[0044] FIG. 10 depicts one possible embodiment for automating the
manufacture of the strips 20 according to the method of FIG. 6. A
conveyor line 30 comprises a plurality of supports 31 upon which
the strips 20 are formed. The supports 31 are spaced apart from one
another as illustrated. A plurality of bases 11a-11e are disposed
on the supports 31, and the bases 11a-11e move in the direction
indicated by directional arrow 33 along the conveyor line 30.
[0045] Base 11a illustrates the base which has been cut into a
strip and has already had its lower surface 24 prepared by sealing.
Note that the term "lower surface" is used for consistency with
previous drawings, but the lower surface 24 is actually facing
upwards in FIG. 10, because the bases 11a-11e are inverted on the
conveyor line 30.
[0046] Base 11b is in the process of having spikes 13 installed. In
this regard, a device 34 that is known in the art installs spikes
through the base. Base 11c depicts the spikes 13 post-installation.
The heads 15 of the spikes 13 are visible on the lower surface 24
of the base 11e. The spikes 13 are spaced apart such that the tips
(not shown) extend into openings 32 between the supports 31.
[0047] Base 11d depicts a roll 35 of tape 22 being applied to the
lower surface 24. The roll 35 is rolled in the direction shown by
directional arrow 36, such that the majority of the lower surface
24 is covered with the tape 22.
[0048] Base 11e depicts a roller 37 rolling across the tape 22 to
compress the tape 72 to the base 11e. The roller moves
longitudinally along the base 11e as indicated by directional arrow
38. The roller 37 is heavy enough to induce a good adherence
between the tape 22 and the base 11e.
[0049] FIG. 11 is an enlarged end view of the carpet strip of FIG.
9, shown installed on the floor 25. Even when installing carpet on
a generally smooth and flat concrete slab, the floor 25 is not
perfectly smooth or flat, and oftentimes there are irregularities
in the floor 25 surface.
[0050] FIG. 12 is an enlarged detail view of the carpet strip of
FIG. 11, taken along detail view "A" of FIG. 11. Irregularity 41 is
an exemplary protrusion in the floor 25. The resilient (i.e.,
spongy) nature of the tape 22, coupled with the thickness of the
tape 22 causes it to conform to the irregularity 41. In this
regard, the lower surface 17 of the tape 22 adheres to the
irregularity 41.
[0051] Further, although the spikes 13 when installed in the base
11 are intended to be recessed into the lower surface 24 of the
base, often the heads 15 of the spikes may protrude slightly from
the lower surface 24, as illustrated by corner 40 of the head 15.
The resilient nature and thickness of the tape 22 again causes it
to conform to the extending corner 40 and generate a good seal
between the upper surface 18 of the tape and the lower surface 24
of the base 11.
* * * * *