Patent Application
20070275207
The invention will now be further described by way of example only and with reference to the drawings, which are briefly described as follows:
With reference to
As shown, in the illustrated exemplary embodiment, the carpet tile 10 includes a tufted, level cut pile carpet, primary carpet, carpet surface, or carpet face 12 preferably having tufts 14, a tufting substrate or primary backing 16, and a precoat or tuft bind layer or coating 18. As is well known in the tufting arts, the tufts are tufted through the primary backing and then held in place by the precoat. The carpet face or exterior carpet layer 12 is disposed in overlying relation to a single or multi-layer particle backing structure 20 as will be described further hereinafter incorporating a mass of particles or crumbs, for example, particles or crumbs of virgin, recycled, recyclable, natural, biobased, biodegradable, renewable, other environmentally friendly or environmentally responsible materials, and/or the like materials such as foam and/or rubber and/or cork and/or carpet particles or crumbs together with at least one optional adhesive or binder and may also include other additives fillers, agents, particles, fibers, and/or the like.
As will be appreciated, the term “carpet” used in reference to the carpet surface or carpet face 12 of the present invention is intended to refer to carpet in its general meaning including, for example, tufted, woven, bonded, nonwoven, flocked, needled, needle punched, knit, and/or the like having, for example, a pile or nap surface such as pile yarns or fibers, for example, loop pile, cut pile, cut and loop pile, level pile, multi-level pile, textured pile, sculpted pile, treated pile, and/or the like. The carpet tile, modular flooring, or the like may be or may include, for example, flat yarn, twisted yarn, textured yarn, level loop, multi-level loop, Berber, broadloom, bulked continuous filament non-texturized yarn, bulked continuous filament texturized yarn, cut pile, cut and loop pile, wool, Nylon, olefin, polyester, filament fiber, staple fiber, frieze yarn, heat-set yarn, heat-set Nylon, heat-set olefin, heat-set polyester, indoor, indoor/outdoor, outdoor, loop pile, fiber pile, yarn pile, nap, single ply yarn, multiple ply yarn, plush, velvet-plush, Saxony, natural Sisal, synthetic sisal, wool sisal, sisal like, Nylon/wool blend sisal, tufted, woven, nonwoven, knit, needle punched, bonded, fusion bonded, latex bonded, hot melt bonded, non-heat-set yarn, spun yarn, filament yarn, singles yarn, plied yarn, sheared, brushed, steamed, bulked, scanned, treated, heat treated, hot fluid treated, chemical treated, dyed, piece dyed, yarn dyed, jet dyed, tile dyed, printed, needle punched polypropylene, needle punched Nylon, needle punched multiple denier, recycled polymer yarn, recycled polymer fiber, biobased polymer yarn, biobased polymer fiber, antistatic yarn, antistatic fiber, single lobe fiber, multiple lobe fiber, high luster, low luster, acrylic fiber, acrylic yarn, acrylic, modacrylic fiber, modacrylic yarn, modacrylic, acrylic/modacrylic fiber, acrylic/modacrylic yarn, acrylic/modacrylic, precoated, tuft locked, tuft binded, anchor coated, non-precoated, non-tuft locked, non-tuft binded, non-anchor coated, backed, non-backed, antimicrobial, antimicrobial treated, antistatic, antistatic treated, attached cushion, stabilized attached cushion, Axminster, U-shaped tuft, V-shaped tuft, I-shaped tuft, including primary backing, not including primary backing, including secondary backing, not including secondary backing, including primary and secondary backing, including multiple primary backings, including multiple secondary backings, including multiple primary and secondary backings, barber pole yarn coloration, carved, base-relief carved, binded, serged, blended, border, braided, bulked, crimped, burled, reburied, cable, modular carpet, tile, carpet tile, carpet tiles, modular carpet tiles, carpet squares, carpet modules, carpet panels, carved only, carved, fluid carved, chemically carved, mechanically carved, uncarved, inset, inlayed, color fast, printed, dyed, jet dyed, injection dyed, cord, corded, cotton, cotton fiber, cotton yarn, cross dyed, cross seamed, seamed, seamless, cushioned, cushion backed, custom tufted, deep dye fiber, regular dye fiber, combined deep dye and regular dye, delustered fiber, design rug, design, design tile, patterned, differential dyed, differential dye fiber, differential dye yarn, multicolored fiber, multicolored yarn, multicolored, space dyed, space dyed yarn, stabilized, dimensionally stable, free lay, adhesive free, dope dyed, double backed, glue down, full spread, direct glue, direct glue down, drop match, drop matched, monolithic, ashler, quarter turn, checkerboard, rug in a box, Beck dyed, flocked, electrostatic flocked, embossed, extruded, extruded fiber, wet laid, air entangled, water entangled, hydro entangled, fluid entangled, fiber bonded, felted, felt, needle punched, entangled, impregnated, ribbed, veloured, textured, pattern textured, chemically backed, fibrillated, filament, continuous filament, filament yarn, monofilament, film yarn, tape fiber, tape yarn, round yarn, round fiber, velvety, velveteen, chopped fiber, free form, frieze, trackless, textured, twisted yarn, tightly twisted yarn, fringed, gel dyed, greige, grey, grey goods, hand crafted face, machine crafted, machine tufted, hand tufted, machine woven, heat bonded, heather, heathered, high low, multilevel, high and low loop, high cut pile and low loop pile, cut and loop style, inset and carved, inset only, jacquard, jacquard woven, jute, linden, grass, knitted, Leno weave, Leno weave backed, level cut loop, level loop, bright luster, semi-bright luster, semi-dull luster, dull luster, clear, white, light colored, translucent, transparent, match, set drop, set match, half drop, quarter drop, drop match, mended, metallic fiber, jointed, monochromatic, Moresque, multi-filament, multi-level cut loop pile, multi-level loop pile, napped, narrow, needled, needled felt, needle-punched, entangled and compressed, calendered, polyamide, polypropylene, solution dyed, conventional, traditional, industrial, new, unique, stain resistant, easily cleaned, durable, abrasion resistant, mildrew proof, non-allergenic, resilient, oriental face, over tufted, packed dyed, pattern cut pile, pattern loop pile, piece dyed, pigmented, pigmented yarns, pile, pile face, pile nap, non-pile, yarn face, yarn nap, yarn pile, fiber face, fiber nap, fiber pile, pile lifted, pile set, plush finish, velvet cut-pile, polymer, plastic, resin, polymer fiber, polyacrylonitrile, printed, screen printed, rotary printed, sponge printed, ink jet printed, pattern dyed, narrow loom, resist printed, rotary brushed, round wire pile, looped pile, uncut pile yarn, scribed, scrimped, seam sealed, salt-toned, two-toned, overcast stitched, shag, side seamed, skein dyed, solution dyed, yarn dyed, continuous dyed, spun, spun dyed, staple yarn, stock dyed, tack dyed, tip sheared, edge sheared, tone on tone, unitary backed, suede, velvet cut pile, wall-to-wall, graphics tufted, Wilton woven, Axminster woven, fusion bonded, servo tufted, loop pile tufted, cut pile tufted, needle punched polypropylene or polyester, non-woven polypropylene or polyester, woollen system yarn, worsted yarn, and/or the like. The above list of carpets, carpet tiles, carpet types, faces, yarns, fibers, finishes, etc. is exemplary only and not limiting. For example, the carpet tile of the present invention is not limited to any particular formation technique, yarn type, backing, or the like. In this regard, it is to be understood that carpet face may include any number of textiles, fabrics, materials, floorings, and/or the like commonly referred to as carpet, used as carpet, known as carpet, or the like. By way of example only, and not limitation, at least one process for forming a bonded carpet (like in
The carpet 12 is preferably a pile face carpet, such as loop pile, cut pile, or cut and loop pile. By way of example only, one contemplated carpet is a tufted cut pile carpet. Another contemplated carpet is a loop pile tufted carpet. Still another contemplated carpet is a cut pile bonded carpet. Still yet another carpet is an Axminster woven carpet. Another exemplary carpet is a Wilton woven carpet. The carpet 12 may be either of solid coloration, heather and/or may have a decorative coloration, image, pattern or design woven, tufted, formed, printed and/or dyed thereon. For example, a pattern, design, color, shade, or the like may be formed by using colored yarns such as yarn dyed or solution dyed yarn, formed by piece dyeing, formed by printing, or may be jet dyed on a carpet made, for example, from white or light colored yarn or fiber Any printing, dyeing or other coloration may be done, for example, prior to carpet formation, during carpet formation, following carpet formation, prior to carpet tile, tile precursor, or tile product formation, during formation, and/or after formation.
As previously indicated, the precoat 18 preferably penetrates, encapsulates, or covers the exposed bottom of the tufts 14 and the exposed bottom of the primary backing 16 to hold the tufts 14 in place and to serve as a bond promoting agent for bonding the carpet 12 to the crumb or particle backing 20, and more particularly to bond to and be compatible with the binder or binders 24 in the backing 20. The precoat 18 is preferably compatible with the binder 24 or binders in backing 20. For example, precoat 18 may be, for example, a latex or urethane based precoat, such as a polyurethane precoat, compatible with a urethane based binder, such as, an MDI binder. The binder may be comprised of any of several different materials. For example, the binder may be a liquid, fiber or powdered binder material such as a polyurethane diphenylmethane diisocyanate (MDI) binder. Preferably it is selected from the group consisting of 4,4-methylene di-p-phenylene isocyanate (4,4′-MDI) polyurethane one- and two-component adhesives. Advantageously the binder is a solvent-free, one component (moisture curing) polyurethane adhesive. The binder may be or may include resins, polymers, plastics, prepolymers, primers, or the like. Such binder may typically be present at a level of from about 2 to 40%. Alternatively the binder may be a hot melt binder and is desirably present at a level of from about 2 to 40%. When powdered elastomer crumb is included in the backing and the binder is a one component polyurethane adhesive, the binder level preferably lies in the range from about 5 to 20%. Binder levels of less than about 2% and greater than about 40% may be employed as may be determined by routine experimentation. The backing may also include one or more additives such as anti-microbial additives, anti-flammability additives, pigments, such as iron oxide, and anti-static additives, such as carbon fibers, fillers, fibers, colorants, dyes, and/or the like.
Although
The adhesive or binder 24 on crumbs or particles 22 of particle backing 20 of
The add on weights of a precoat layer are usually less than the add on weights of a tiecoat or adhesive layer. For example, a typical precoat add on is about 2 to 20 oz/yd2 and a typical tiecoat add on is from about 15 to 50 oz/yd2. The precoat 18 of the present invention may be one or more layers of precoat material. If the precoat 18, 60 is to act as both a precoat and tiecoat, a heavier add on of precoat may be used. Also, the precoat composition or chemistry may be more like a tiecoat or adhesive when the precoat is used as a tiecoat.
As previously indicated, the backing structure 20 preferably is formed from a mass of crumbs or particles 22, such as renewable materials, recycled materials, and/or virgin materials, for example, such as cork and/or foam and/or rubber particles, preferably recycled cork and/or recycled foam and/or recycled rubber particles attached together using a binder material 24 such as a resilient or hard binder that bonds each particle to adjacent particles alone or together with other materials, agents, fillers, additives, and/or the like. The crumbs or particles 22 are preferably of a substantially irregular fractal surface geometry so as to provide a high surface area for bonding. However, cylindrical, cigar, polygonal, spheroidal, pellet, disc, rod, and/or other relatively smooth surface geometries may be used if desired. Also, the crumbs 22 may be solid, resilient, hollow, perforated, mesh, foam, fibrous, or the like. For example, crumbs 22 may be compressible and/or noncompressible spherical particles such as rubber or ceramic spheres may be employed. In the embodiment illustrated, the binder 24 also bonds the backing structure 20 to the precoat 18 on the underside of carpet layer 12. As will be appreciated, within the backing structure 20, preferably interstitial voids exist between the crumbs or particles, some of which may be partially or fully filled with the binder, fillers, additives, etc. If desired, maintaining voids and/or using a resilient binder may provide substantial resiliency and cushioning. A certain number of voids may also reduce mass, reduce cost, increase flexibility, enhance lateral grip, reduce creep, and/or the like. At least when using a liquid binder, it is preferred that each of the particles of the backing be encapsulated with at least a thin layer of binder. This aids in bonding the particles together and in bonding the backing 20 to the face composite 12.
In the event that the particles 22 of the backing structure 20 are rubber, recycled SBR rubber, recycled nitrile rubber, or recycled EPDM rubber or polymer may be preferred, and recycled EPDM rubber or polymer may be most preferred. By way of example, one contemplated source of EPDM polymer is recycled weather stripping. Such EPDM may be either of hard or resilient (foam) character. By way of example only, one contemplated source for nitrile rubber is from recycled industrial mats. The rental industrial mat segment is an ideal source of raw material for the rubber crumbs or particles because it ensures that low bleed, low staining nitrile rubber is used as the starting point for the production of the carpet tile. Recycled SBR rubber from recycled tires may also be used if desired. Other rubber materials (solid or foam) may be used. In the event that the particles of the backing structure are foam, recycled EPDM foam or cellular polyurethane foam may be preferred. Resilient materials other than foam may be used. For example, compressible or resilient materials such as cork (which is also a renewable material), hollow particles like hollow spheres, rubber, gel particles, gel filled particles or spheres, and/or the like may be used.
For example, if one uses 100% EPDM particles, then they may need to use up to 10% by weight binder; if one uses a mixture of EPDM particles and cork particles, then they may need to use up to 15% by weight binder; while, if one uses an equal mixture by volume of recycled EPDM particles, cork particles, and recycled carpet tile waste particles, then they may need up to 20% by weight binder to fully cover each particle, bind the particles together, and to bind the particle backing to the carpet and to any secondary backing. In accordance with one preferred example, a particle backing 20 is made up of a mixture of particles of ⅓ cork crumb, ⅓ recycled EPDM rubber crumb, and ⅓ recycled carpet tile crumb based on volume as the densities of these materials varies greatly together with about 5% to about 15% polyurethane MDI binder by weight. Such a particle backing has an aesthetically pleasing appearance due to the mixture of, for example, tan colored cork particles, black colored rubber particles, and brown colored recycled carpet tile particles. Preferably, the binder coats the surfaces of the particles but does not fill all of the voids between the coated particles in the particle backing.
It is contemplated that the size of backing structure particles or crumbs 22, for example, recycled material particles, renewable resource particles, and/or virgin particles, such as recycled foam, carpet, rubber and/or cork particles, utilized preferably range from about 0.01 to about 15 mm, more preferably from about 0.04 mm to about 12 mm, still more preferably from about 0.15 mm to about 10 mm, and yet more preferably from about 0.3 mm to about 8 mm, and most preferably from about 0.5 mm to about 6 mm. For example, if the particle backing is to be about ½ inch thick, then the crumbs should preferably be sized about ¼ inch or less. If the particle backing is to be about ¼ inch thick, the crumbs should preferably be sized about ⅛ inch or less. A low fines crumb may be preferred. However, smaller and/or larger particle sizes may be used if desired. Generally, the size of particle is selected to be as large as possible for the use and properties required.
Even though particles or crumbs of a certain size may be preferred, the particular particle backing may include a majority of particles of the preferred size or range of size but may also include a certain amount of particles below and above the preferred size or range of size. For example, if a screen or mesh is used to filter the particles, then the screen or mesh only sets an upper limit on particle size in one dimension of the particles. For instance, cylindrical particles may have a small diameter but a long length. Also, smaller particles will fit through the mesh or screen. It has been found that particle size can be chosen to give different amounts of resilience, cushion, flexibility, and/or the like in the tile product. Larger particles generally provide greater resilience. Particles of a desired size may be mixed with powder of the same material or a different material to provide a greater tear resistance. Powder may increase the tensile strength for a given binder level. The use of other additives 28 in, for example, powder, fiber, or liquid form may provide the same or different advantages. Suitable additives include, but are not limited to, anti-microbial materials, anti-flammability additives, odorants, colorants or pigments such as iron oxide powder, anti-static additives such as carbon fibers, fillers, such as calcium carbonate, fly ash, sand, used foundry sand, silica, fibers, such as natural or synthetic fibers, for example, glass or Nylon, polymers, plastics, resins, adhesives, carbon black, charcoal, and/or other generally known agents, fillers, additives and/or the like.
Also, one may combine hard and resilient chips, particles or crumbs of the same material or different materials. For example, one may mix foam EPDM particles with solid filler particles and with liquid or powder binder.
The adhesive or binder 24 used to adjoin the particles 22 of backing 20 may be one or more of a variety of binding, bonding, adhering, and the like materials, systems, mixtures, prepolymers, blends, components, and the like. For example, the binder may be a water curing, heat setting or thermoplastic type material. Depending on the process utilized to manufacture the backing, the binder can be, for example, in liquid, fiber, pellet, particle, or powder form. Preferably, the binder is selected from one of the following types: water based adhesives, polyurethane reactive hot melts, copolyester or copolyamide reactive and thermoplastic hot melts, urethane MDI binder, and 4,4-methylene di-p-phenylene isocyanate (4,4′-MDI) polyurethane one- or two-component adhesives. Although not preferred, depending on the precoat 18 and the type of particles or crumbs 22, the binder 24 may be EVA, PVC, SBR, other thermoset adhesives, resins, plastics, polymers, low melts, fibers, particles, pellets, and/or the like which bond or fuse the particles or crumbs 22 to one another.
It is preferred that the binder 24 has good adhesive properties to ensure that the particles 22 are well bound, and it may be additionally desirable that sufficient free binder is provided to be capable of forming a physical or chemical bond to the lower exterior surface of carpet 12, precoat 18, tufts 14, or backing 16, to any secondary backings (for example, 50 in
In the illustrated exemplary embodiment of
If the crumbs or particles 22 of backing 20 are made from or coated with a material that will bind the particles together during particle backing formation, then addition of binder 24 may not be required. For example, if the particles 22 are recycled waste carpet tile particles including or coated with hot melt adhesive or hot melt adhesive components during particle formation, then the hot melt components of particles 22 may be sufficient to bond the particles 22 together and to carpet 12 (precoat 18). In other words, the particles may be self-binding or the binder may form part of the particles or crumbs 22.
Generally, there is an inverse relationship between the binder content and size of the particles 22 and between the binder content and pressure applied to the binder/particle mixture while forming the backing structure 20. Therefore, as the particle size and the pressure increase, the binder content normally decreases. The binder content also depends on other factors, such as the type of binder, the particle material or materials used, the type of carpet, desired resiliency, and the like, and can be determined by routine experimentation. As binder is usually an expensive material, one would not use more binder than necessary.
For example, the binder may be a liquid polyurethane MDI binder, in which case it is preferably present at a level of from about 2% to 20% by weight, more preferably from about 2% to 12% by weight if, for example, the backing consists primarily of chips or granules. The binder may, for example, contain further additives or materials that are in liquid form and are compatible with the binder, such as water, catalyst, colorants, plasticizers, perfumes, and/or the like. The binder may also contain other additives provided that they are suitable for addition in a liquid medium.
In another example, the binder may alternatively be a thermoplastic or thermosetting powder, such as an adhesive or hot melt powder, in which case it is preferably present at a level from about 2% to 20% by weight, more preferably from about 2% to 12% by weight if the backing consists primarily of chips or granules. A powdered binder may also contain other additives provided that they are suitable for addition in a powder medium.
In accordance with at least selected embodiments, the preferred ranges for binder content may thus be summarized as follows:
Backing of chips/granules: binder content in range from about 2% to 20% by weight, preferably from about 2% to 12% by weight with, for example, an MDI binder or preferably from about 2% to 12% by weight with, for example, a hot melt binder. Backing with 10% powder: binder content in range from about 2% to 40% by weight, preferably from about 9% to 20% by weight.
In certain cases, a binder content of less than about 2% or more than about 40% by weight may be employed. High binder contents may lead to the formation of a skin, reduction or elimination of voids, higher cost, longer set times, slower processing speeds, higher processing temperatures, and/or the like. In accordance with another aspect of the particle/binder backing, a very heavy (dense) particle or crumb material (or materials) may be used with a very light (for example, powder) binder or adhesive. Hence, about 1% or more by volume binder may be sufficient. For instance, a hardback tile product may have a dense particle/binder backing with a low binder content. Conversely, one may use very light particles or crumbs with a relatively heavy binder or adhesive. Hence, the ratio of binder to particles may vary between about 0/100 binder to particles (no binder, self-binding particles) by weight or by volume to about 90/10 ratio of binder to particles by weight or by volume, preferably from about 5/95 to 25/75 ratio of binder to particles by weight.
A process for making the carpet tile or modular flooring 10 of
To aid in establishing a uniform deposit of particles and binder across the carrier belt 38, the doctor blade 46 or other suitable levelling device is positioned downstream of the deposit station. The doctor blade 46 or other levelling device such as a doctor roll, knife, air knife, or the like may reciprocate, oscillate, have a moving polymer film cover, and/or the like to help set the level of particles on the belt, to flatten and/or compress the particles on the belt, to keep the doctor blade or roller clean (for example, to prevent build-up of particles, binder and/or additives on the blade), and the like.
If the binder 24, particles 22, and additives 28 are all in particle, powder or granular form (rather than liquid form), one may not be as concerned with keeping the blade 46 or roller clean.
It is contemplated that any of a variety of devices may be used to apply binder 24, particles 22, and/or additives 28 to belt 38 and to meter or set the height of the layer of such materials on the belt 38. For example,
Deposit head 45 of
Doctor blade 46 may doctor the level of the particle/binder/additive mixture to about 1.00 inch, 0.50 inch, 0.25 inch, 0.15 inch, 0.12 inch, 0.10 inch, 0.06 inch, 0.03 inch, or the like. Walls or stops (not shown) running along the length of the belt 38 in the area of doctor blade 46 may serve to keep the particle/binder/additive mixture within set boundaries on the belt.
At set intervals, for example, at the end of each shift, the mixer 44, deposit head 45, other feeds, doctor blade 46, and the like may need to be cleaned to remove any particle, binder, or additive build-up. Water, cleaning agents and/or solvents may need to be used to clean these items depending on the particles, binder, and/or additives in use. Also, when switching from one mixture to another, these items may be cleaned.
The carrier belt 38, like belt 36, is made, for example, of hardened rubber, metal, glass, non-stick polytetrafluoroethylene (PTFE)-coated woven glass fabric, or the like. The belt may be coated with, for example, PTFE, silicone, latex, acrylics, textiles, films, and/or other materials or release agents to prevent the applied materials from sticking to it. In use, the carrier belt 38 advances in the direction of the arrows (clockwise rotation). This movement may be either stepwise or continuous depending upon the nature of the tile product being formed. As illustrated, the carrier belt 38 is disposed in opposing relation to motor driven compression belt 36 which moves in reverse angular relation to the carrier belt 38 to establish a nip zone between the belts in the vicinity of heating and/or cooling elements 40. Materials deposited on the carrier belt 38 thus undergo a degree of compression between the carrier belt 38 and the compression belt 36 while simultaneously being heated or cooled.
In the illustrated process, a precoated or non-precoated (greige goods) carpet material forming at least part of the carpet surface 12 is conveyed from a roll 30 through coater 32 such as a roll coater, reverse roll coater, sprayer, extruder, or the like wherein the precoat or film forming composition 18 is optionally applied to the back of carpet 12. The film-forming composition 18 may be added in one or more steps and is preferably a liquid latex or urethane such as is readily available for precoating the back of greige (grey) goods and the like although acrylics and other suitable tuft lock, tuft bind, adhesives, binders, or compositions may likewise be utilized if desired. By way of example only, and not limitation, suitable precoat compositions are believed to be urethane, polyurethane, latex, nitrile latex, natural latex, diphenylmethane diisocyanate (MDI), polymeric MDI (PMDI), 4,4′-MDI, 2,4′-MDI, 2,2′-MDI, non-isomer-specific MDI, water dispersion urethane precoat system, thermoset adhesive, thermoplastic adhesive, MDI binding adhesive, binder, hot melt adhesive, bitumen hot melt, polyurethane adhesive, urethane reactive hot melt, SBR, EVA, PVC, water based adhesive, and/or the like. It is preferred that the precoat 18 be compatible with and bind to binder 24 of backing 20, especially when there are no adhesive or tiecoat layers between the precoat 18 and binder 24. For example, a urethane precoat and urethane binder, a latex precoat and urethane binder, an EVA precoat and EVA binder, a PVC precoat and PVC binder, an MDI precoat and MDI binder, toluene diisocyanate (TDI) precoat and TDI binder, etc. It is preferred that the precoat, binder, adhesive, tiecoat, secondary coating, and/or the like, be environmentally friendly, environmentally responsible, low VOC, water based, biobased, biodegradable, natural, renewable, recyclable, recycled, moisture cured, non-toxic, ambient temperature cured, nonfugitive, non-volatile, nonreactive, zero risk environment, resilient, elastomeric, formaldehyde free, solvent free, PVC-free, and/or the like if possible or desirable.
After exiting the coater 32, the precoated carpet 12 is then passed through a curing station 34 such as a heater, oven, fan, dryer, other curing equipment, or the like to cure the applied precoat composition to form the lower exterior carpet surface 18 as previously described. The carpet 12 with the cured precoat 18 is then delivered in overlying relation to the particle/binder composition on the carrier belt 38 for subsequent compression and heating and/or cooling between the carrier belt 38 and the compression belt 36. Of course, it is to be understood that the coating or precoating of the carpet or greige goods need not be carried out in the same processing line as the setting (heated compression) of the particle backing 20. In fact, such steps are likely to be carried out in separate processing lines to facilitate processing freedom. Also, the precoat 18 may not be required as shown in
After the precoat layer 18 of carpet 12 or the non-precoated carpet 12 is oriented on top of the particle/binder/additive composition, the pressure and heat (and/or cooling) applied between the opposing belts 36, 38 causes the binder to bond or fuse the particles 22 together thereby forming a stable backing structure 20 of desired thickness and resilience. In this regard, the applied pressure is preferably in the range of from about 0.01 to about 50 pounds per square inch or greater, more preferably from about 1 to 10 pounds per square inch, and the temperature is preferably from about 250 to about 375 degrees Fahrenheit although higher or lower temperatures may be used depending upon the materials of construction and pressure utilized. The heating or cooling platen 40 is preferably divided into a plurality of sections, for example, 40A, 40B, and 40C as shown in
Although only platen 40 is shown in
The combination of the precoat 18 and the binder 24 in the backing structure 20 may concurrently bond the carpet 12 to the backing structure 20. The layered structure formed has the configuration illustrated in
With reference again to
Likewise, with respect to
With respect to
If layer 50 is a preformed film, such as a thin polypropylene film, acrylic film, latex film, urethane film, or the like, then preformed film 50 may be added to belt 38 by supply, roll, feed, let off, or the like 48 or 84 upstream of the addition of the particle/binder/additive mixture. A thin polypropylene film such as a black or clear film may be preferred to keep binder 24 from contacting and sticking to belt 38. The carpet 12 tends to keep the binder 24 from contacting the belt 36. Alternatively, layer 50, 54, 60, 150, 160, or the like may be or may be covered by a thin, friction enhancing coating material which may provide enhanced lateral grip and/or vertical stick to the floor or sub-floor. It is contemplated that one or more friction enhancing materials or layers may optionally be added to the bottom of the carpet tiles. Such friction enhancing materials are described, for example, in U.S. patent application Ser. No. 10/209,050 (US Published Application US 2004/0022991) incorporated by reference herein. Preferably, such friction enhancing materials provide additional lateral grip and some vertical stick. Also, backing 20 and/or the other backing layers or materials may include magnetic or magnetizable particles or material to provide a magnetic attraction to, for example, metal raised access flooring. Further, the friction enhancing material may be covered with a releasable, removable, cover sheet to provide a peel-n-stick tile product. The friction enhancing material may be added before, during or after tile product formation.
With reference to
Secondary backing or release layer or textile 52 may be added to or laid on belt 38 via supply, feed, let off, or roll 48, 84, 48′, 84′, 48″, 84″ of
Like layer 52 of tile product 10B of
Layer 50 is bound, bonded, attached, or adhered to layer 52 of tile product 10C of
Like layer 50 of
Layer or backing 52 of tile product 10D of
With reference to
Layers, coating, backings, or the like 50, 150, of
With reference again to
Certain enhanced tufting substrates or primary backings 16 such as described, for example, in U.S. Pat. No. 6,866,912, hereby incorporated by reference herein, can reduce or eliminate the need for a precoat or tuft lock layer. If desired, a very thin primer material or layer can be added to the base of carpet 12 (at coater 32 or 90) to enhance the bond between carpet 12 and backing 20.
Although
Of course, if desired, an additional layer of adhesive such as a thermoset or thermoplastic resilient adhesive, for example, a thermoset urethane, a hot melt urethane, polyester, polyamide, or the like may be added at the intersection between the particle/binder backing 20 and the lower surface or precoat 18 of carpet 12. Such an adhesive 60 may further stabilize the structure and provide enhanced protection against delamination. For example, an adhesive or tiecoat layer 60, such as a urethane hot melt, reactive urethane hot melt, thermoset urethane, or the like, may be added in place of precoat 18, between precoat 18 and particle backing 20 (
With reference to
Aside from fused chips, particles or crumbs, such as rubber and foam with binder, preferably recycled rubber and/or foam with binder, it is also contemplated that carpet tile of the present invention may incorporate preformed backing structures of, for example, chips, crumbs, binder, and additives, such as, so-called “rebond” or “bonded” foam wherein relatively small chips or pieces of scrap foam are formed into sheets with resilient binder at least between the foam pieces.
The process illustrated in
As with respect to
An alternative exemplary process for use in forming the illustrated and described tile structures is shown in
As with respect to
The present invention is also readily adaptable to tile structures requiring substantial levels of internal dimensional stability such as, for example, free lay carpet tile, cushion back carpet tile, tile blanks to be dyed, and the like. One exemplary structure for a carpet tile 110 intended to have such internal dimensional stability is illustrated in
An exemplary process for making the carpet tile 110 of
The carrier belt 138, like belt 136, is made, for example, of PTFE-coated woven glass fabric to prevent the applied materials from sticking to it. In use, the carrier belt 138 advances in the direction of the arrows (clockwise as shown). This movement may be either stepwise or continuous depending upon the nature of the tile product being formed. The carrier belt 138 may have a smooth or textured outer surface. A textured surface of the belt 138 may impart a texture to the base of tile product 110. As illustrated, the carrier belt 138 is disposed in opposing relation to motor driven compression belt 136 which moves in reverse angular relation to the carrier belt (counter clockwise as shown) to establish a nip zone between the belts in the vicinity of heating and/or cooling elements 140. Materials deposited on the carrier belt 138 thus undergo a degree of compression between the carrier belt 138 and the compression belt 136 while simultaneously being heated and/or cooled.
In the illustrated process of
After the carpet 112 is oriented on top of the particle/binder/additive composition, the pressure, heat, cold, moisture, and/or the like applied between the opposing belts causes the binder to bond or fuse the particles together thereby forming a stable backing structure 120 adhered to both sides of the stabilizing layer 162 and to the carpet 112. In this regard the applied pressure is preferably in the range of from about 0.01 to about 50 pounds per square inch, preferably from about 0.1 to about 20 pounds per square inch, and most preferably between about 2 to about 8 pounds per square inch to avoid excess pressure, pile crush, etc. and the temperature is preferably in the range of from about 200 to 500 degrees Farenheit, more preferably, about 250 to 375 degrees Fahrenheit. The stabilized composite 120 is concurrently bonded to the carpet 112 and the backing 152, 150, 160 by the binder in combination with any applied adhesive. After formation, the resultant composite structure or construction may be delivered to a tile cutter 142 or accumulated on a roll (not shown) if it is to be cut later.
The indexing or continuous movement of belts 136, 138, depends on factors including the tile product to be produced, the amount of compression required, the speed of setting or curing of the binder, additives, adhesives, precoats, films, coatings, and/or the like. For example, a section or increment of tile product composite can sit between belts 136, 138 under pressure and heat for, for example, anywhere from about 1 to 60 minutes, preferably 2 to 30 minutes, more preferably less than 5 minutes. The time to set or cure can be reduced by, for example, adding water and/or other catalyst or accelerators to the binder, particle/binder/additive mix, particle/binder mix, particles, additives, and/or the like. For example, one may add a small quantity of water and/or catalyst to an MDI binder to speed up the set time from about 20 minutes to about 10 minutes. Also, increases in pressure, temperature can reduce set time.
Even though belts 136, 138 can be driven in increments or steps, it is preferred that they are run continuously for an in-line, continuous operation. For example, belts 136, 138 may form part of a continuous double belt laminator system and may be run, for example, at 10 feet per minute, 20 feet per minute, 40 feet per minute, or the like. It may be preferred that the carpet face particle backing composite have an overall dwell time, for example, under heat and pressure of between about 1 to 20 minutes, more preferred 2 to 10 minutes, most preferred about 3 to 8 minutes.
Also, it may be preferred that the tile product 110 include a lower or bottom coating, film, layer, and/or the like such as 150, 160, or 120C. It may be most preferred that tile product 110 have a lower coating of a friction enhancing composition.
Aside from in-line formed particle backings of, for example, virgin, recycled, renewable, or recyclable particles such as cork, carpet, carpet tile, rubber and foam, it is also contemplated that carpet tiles of the present invention may incorporate preformed particle backing structures of such virgin, renewable, recyclable, recycled, natural, synthetic, and/or the like particles, for example, preformed particle/binder/additive backings or backing layers, such as so-called “rebond” or “bonded” foam, such as rebond polyurethane foam, wherein relatively small pieces of scrap foam are formed into sheets with resilient binder between the foam pieces.
As with respect to
For example, with reference to
Of course it is to be understood that any number or other embodiments may be utilized for the carpet tiles or modular flooring of the present invention depending upon contemplated use and performance requirements. By way of example only, one contemplated alternative construction is illustrated in
With reference to
With reference to
With reference to
With reference to
With reference to
With reference again to
With reference again to
With reference to
With reference again to
With reference again to
With reference again to
Another contemplated tile construction is illustrated in
Yet another contemplated tile construction is illustrated in
As will be appreciated, if desired, additional layers of adhesive such as hot melt urethane, polyester and/or polyamide or the like may be added at one or more of the intersections between any of the layers in any of the illustrated embodiments. Thus, by way of example, a layer of adhesive may be added between the backing sheet and the adjacent backing layer and/or between the lower backing layer and the stabilizing layer (if utilized) and/or between the stabilizing layer (if utilized) and the overlying backing layer (if present). Likewise, it is contemplated that in any of the illustrated and/or described embodiments that the structure may be formed with or without a fibrous backing sheet. Also, additional binder may be added to the surface of any layers, sheets, or the like, such as preformed particle sheets such as crumb rubber or rebond foam, or may be used as an adhesive, tiecoat, etc.
One contemplated benefit of the carpet tile constructions of the present invention is the ability to incorporate large percentages of recycled, renewable, recyclable, natural, biodegradable, biobased, environmentally friendly, environmentally responsible, and/or the like materials such as recycled waste products, such as recycled weather stripping, recycled mats, recycled tires, recycled carpet waste, and such as renewable resources such as natural products such as cork or wood, and/or the like. By way of example only, recycled particle or crumb materials such as ground up carpet may be blended with the rubber particles and binder prior to being deposited in the desired layered relation. In such a process the carpet waste may not undergo melting but may rather form a constituent of the resilient matrix forming the backing. Thus, relatively large amounts of carpet waste may be incorporated without negatively impacting resiliency since the individual rubber particles are not melted, voids remain, etc. In one example, the particle binder mixture is made up of one-third cork particles, one-third recycled rubber particles, and one-third recycled surface covering particles. The one-third proportion can be based on either weight or volume. Binder such as MDI binder bonds the three different types of particles together.
Another benefit of the constructions of the present invention is that the tile products of the present invention (and any waste) may be recycled and used as particles or crumbs in the particle backings of the present invention. Thus, for example, the tile products 10, 110, 210, 310, 410 may be ground up and recycled as new backing material.
With reference to
It is also contemplated that the materials forming the backing structures may themselves be used to provide a portion of an aesthetically pleasing tile show surface. By way of example only, in
The materials forming the backing structures may also be used to provide a portion of an aesthetically pleasing tile show surface by using show surface fabric constituents of relatively open weave or knit construction (including mesh or net-like scrims) such that the backing is visible through the show surface fabric. Such open fabrics may be used alone or in combination with outboard borders.
The bottom surface of any of the tile structures, constructions, or products of the present invention may also be textured such as by embossing to, for example, enhance surface friction or the like.
In accordance with one possible embodiment of the present invention, the construction of a carpet face and a backing of at least one layer of agglomerated, adjoined particles are cured, cut into floor tile blanks, colored, printed or dyed, then cured, sheared, packaged, shipped, and the like.
It is usually easier to print or dye in register by printing or dyeing tile blanks or modular blanks as contrasted to printing or dyeing in broadloom form. A backed floor tile blank (carpet face, particle/binder backing, with or without an additional stabilizing layer, adhesive layer, textile backing, friction enhancing backing, and/or the like) with a light color or white textile face adapted to be colored, printed, dyed, or the like is adapted to be colored, dyed, printed, textured, treated, embossed, and can have, for example, an image, design or pattern applied thereto with relative precision (for example, by placing a square tile blank in a jig) to produce, for example, a floor tile with an image, pattern, or design which will register with an adjacent image, pattern, or design of an abutting floor tile in a floor tile installation. In this manner, a large image, pattern or design can be split up into a number of parts with each part on a separate tile. Alternatively, a tile pattern that is intended to mate with at least certain elements of an adjacent tile pattern can do so with precision and in registration to provide a very pleasing, seamless, appearance to the overall installation.
Similarly, a tile blank or modular blank with a carpet face of show surface and a particle/binder backing may be cured and then colored, printed, dyed, and/or the like by, for example, a printing process (for example, transfer printing, screen printing, rotary printing, or the like).
Most dyeing and printing is done on white or light colored materials (substrates). Nevertheless, one can also print light colors on a dark face material.
In accordance with at least one embodiment of the present invention, the face and/or backing of the carpet tiles of the present invention meets or exceeds industry standards of, for example, flammability, smoke, toxicity, soil protection, antimicrobial, odour, VOC, smoke density, pill test, lightfastness, crocking, static electricity, dimensional stability, Aachen test, dye fastness, durability, caster chair test, face weight, height, flexibility, size, cup, curl, bow, bias, skew, height variation, dimensional variation, stain protection, soil resistance, stain resistance, cleanability, commercial rating, residential rating, cushion, resilience, drape, seamability, appearance retention, compression, compression set, recycled content, recyclable content, renewable material content, and/or other industry standards, environmental standards, test ratings, and/or the like. For example, floor covering industry standards and/or specifications, more particularly, commercial flooring standards, residential flooring standards, institutional flooring standards (such as hospital, education and/or government standards), hospitality flooring standards, retail flooring standards, tile standards, and/or the like. For example, the carpet tile may be PVC-free.
In accordance with at least one embodiment of the present invention, it is preferred that the particles and/or crumbs in the particle/binder backing structure or layer be about 6 mm or less (powder or granules).
The particle/binder backing of at least one embodiment of the present invention is cured at about 100 psi (pounds per square inch) or less, preferably 50 psi or less, more preferably 25 psi or less, most preferably 10 psi or less. A low pressure cured particle/binder backing having some voids between the crumb (particles) and having, for example, crumb ranging in size mainly from about 2 mm to about 6 mm provides lateral grip with smooth and even carpeted surfaces. This lateral grip provides carpet tiles which tend not to creep or walk. Carpet tiles of the present invention having this lateral grip tend to stay in place after installed even without full spread adhesive installation, releasable adhesive installation, double sticky tape installation, and even free-lay or adhesive free installation.
The particles or crumbs of the particle/binder or particle/binder/additive backing of at least certain embodiments of the present invention may be selected from recycled, recyclable, renewable, waste, by-product, reclaimed, and/or virgin materials.
It is preferred to use recycled, recyclable, and/or renewable materials when possible. For example, recycled flooring, recycled foam, recycled rubber, recycled cork, cork, wood, and combinations thereof, are preferable. Recycled flooring such as recycled carpet, recycled carpet tile, recycled waste carpet, recycled carpet, recycled trim waste, recycled carped production waste, and the like can be processed to produce particles or crumbs of less than about 20 mm, preferably less than about 15 mm, more preferably less than about 10 mm, and most preferably less than about 6 mm (powder or granules). Although post consumer recycled content may be preferred, post industrial recycled content, renewable material, recyclable material, bio-based, biodegradable, and other environmental friendly or environmentally responsible materials may be used.
With reference to
Carpet tile, carpet tiles, modular carpet tile, modular flooring, or the like of at least selected embodiments include a carpet face or show surface in overlying relation to a backing of or including adjoined particle elements. In particular, but not exclusively, the carpet tiles incorporate a carpet surface or carpet face, having, for example, a pile or non-pile surface. In one embodiment, the carpet of the carpet tile has a tuft bind or precoat layer, such as a urethane precoat, disposed in overlying relation to a resilient backing formed from a mass, mixture, or slurry, for example, of particles or crumbs, bonded together in adjoined relation by a binder. One or more optional stabilizing and/or backing layers may be included. Methods of making such carpet tiles are also provided.
In accordance with at least one embodiment of forming modular carpet tiles, granule or powder rubber crumb is mixed with binder and applied to a suitable textile surface, is cured, and then cut into the desired size for modular carpet systems. By using the flexibility of the rubber binder system, the physical properties of the backing can be optimized for selected or desired performance.
Given the stringent carpet tile performance requirement of dimensional stability with flatness, it may be preferred to add a stabilization layer to the backing. Normally this layer is a scrim or mat of fiberglass. The crumb/binder backing process can be adapted to apply two layers of crumb, interposing the scrim. The textile surface is applied and processed in, for example, a vulcanization press to form the tile material. The carpet tile composite is then cut into modular tile form.
In accordance with a selected particle backing example, a lower crumb layer is made from 2 mm mesh rubber crumb mixed with 8% binder. This is spread onto the belt at approximately 1.5 kilos per square meter. A layer of 45 g/sq.m glass scrim is laid on. An upper crumb layer is also made from 2 mm mesh rubber crumb mixed with 10% binder and is spread over the scrim. This higher level of binder is to give sufficient free binder to act as an adhesive to the carpet bottom surface and to wet out the scrim to adhere the multi-layer composite together. The carpet textile surface is laid on top. This assembly is passed through a quasi continuous vulcanization press process.
The use of rubber as the principle crumb or particle material gives advantages in flexibility and produces a tile which will lay flat and stay flatter.
The press process may be carried out at elevated temperature to speed up the curing or setting of the binder. This has the benefit of “setting” the tile structure at a relatively high temperature, for example, 120 centigrade. The thermal expansion of the rubber crumb/binder combination is slightly higher than that of the textile carpet surface and this results in a very slight doming of the tile, which may be advantageous when minimal. Also, as the tile is formed at temperatures above that of atmospheric steaming (for example after printing) the thermal stability of the tile is not de-set.
In an alternative embodiment, the textile surface can be inverted and used in place of the lower conveyor. The upper crumb layer is scattered directly onto the textile and the scrim added before the lower crumb layer is scattered. In this case, it may be optional to construct the vulcanization press upside down with the heated platen on the top and the air bag below.
The chemistry of the binder can be modified extensively, along with the size and type of rubber crumb used. For example, calcium carbonate can be added to stiffen the backing. This could be optionally added to one layer for stability and the other layer constructed of soft materials and binder to provide a cushion effect.
Other additives may include anti-flammability, anti-microbial, colour pigments, etc.
While the present invention has been illustrated and described in relation to certain potentially preferred embodiments and practices, it is to be understood that the illustrated and described embodiments and practices are illustrative only not limiting and that the present invention includes such embodiments but is not limited thereto. Rather, it is fully contemplated that modifications and variations to the present invention will no doubt occur to those of skill in the art upon reading the above description and/or through practice of the invention. For example, the particle backing of the present invention may be a preformed composite including a particle backing layer, a stabilizing layer attached to one side of the particle backing layer and a backing material attached to the other side of the particle backing layer (see
The words “comprises/comprising” and the words “having/including” when used herein with reference to the present invention are used to specify the presence of stated features, integers, steps or components but does not preclude the presence or addition of one or more other features, integers, steps, components of groups thereof.
It is appreciated that certain features of the invention, which, for clarity, are described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable sub-combination.
