Patent Grant
9648972
Field of the Invention
The present invention pertains to the art of carpets and artificial turf and, more particularly, to an apparatus for use in seaming carpet or artificial turf sections, as well as a method of utilizing the seaming apparatus. More particularly, the present invention relates to an apparatus and method for using said apparatus in applications where the backing on the carpet or artificial turf is exceedingly dense or thick.
Discussion of the Prior Art
When installing wall-to-wall carpeting, it is common practice to join various carpet sections by seaming abutting edge strips of the carpet sections. There has heretofore been utilized numerous types of seaming arrangements. These known seaming arrangements include sewing the abutting edge strips, adhesively joining the carpet sections through the use of a heat tape, and interconnecting the carpet sections through cleated connectors. In each case, the interconnection of the carpet sections is preformed manually by the installer.
Creating a seam by sewing carpet sections together can be extremely time consuming and can add considerable costs to the installation of the carpet. For these reasons alone, this seaming method is being utilized with less frequency in today's market. Utilizing heat tape in creating carpet seams, on the other hand, is extremely commonplace as it reduces required installation time and is quite cost effective. Unfortunately, drawbacks exist with respect to this seaming method as well. Although the need for additional tools such as a hot iron may be considered a drawback with such a seaming arrangement, the main drawback concerns the fact that it is extremely common for such a carpet seam to fail well before the carpet wears out. This fact is particularly prevalent in seamed wall-to-wall carpet installations where the entire carpet is stretched utilizing a power stretcher since stretching the carpet in this manner subjects the seam to rather large tension forces. In addition, based on the amount of adhesive utilized, high spots can be formed in the carpeted area and the minimization of such spots depends on the expertise of the installer. The concept of utilizing cleated connectors in creating carpet seams has been long before proposed as evidenced by the teachings in U.S. Pat. Nos. 2,552,114, 3,413,678 and 3,760,454. Unfortunately, each of these known arrangements have their associated drawbacks and have therefore not experienced much commercial success. In particular, these cleated connector arrangements are either not designed for use or simply not effective when utilized in power stretched wall-to-wall carpet installations due to their particular structure which enable them to stretch or flex in one or more directions, as well as the manner in which they are mounted to the carpet sections and supporting surfaces. There are also systems and methods for using a seaming apparatus to join two carpet seams in power stretched wall-to-wall installations as evidenced by U.S. Pat. No. 5,800,664 entitled “CARPET SEAMING APPARATUS AND METHOD OF UTILIZING THE SAME” and issued on Sep. 1, 1998, which is hereby incorporated by reference herein in its entirety.
In particular, the prior art carpet seaming methods and apparatuses do not perform adequately when the backing on the carpet, or in some applications artificial turf, is particularly thick or dense, such as with commercial carpeting typically found in offices, retail stores, and banks. The existing seaming apparatuses have short, triangular teeth that do not adequately “seat” or penetrate the backing of denser carpets or artificial turf. Hot melt tape and mesh/glue seaming methods are not desirable in these applications because carpets or artificial turf seamed using these methods are prone to failure and are particularly vulnerable to damage from moisture because the hot melt tape or glue used in these seaming methods are not waterproof.
When Seaming artificial turf for a residential lawn, Golf Course Turf, or Soccer Field/Football Field Turf, a mesh like seam tape, which is non-porous, and is used in conjunction with various adhesives so the adhesive will not seep through. The prior art method employs a two step approach. Existing methods may use a minimum of 12″ wide tape and may use up to 36″ wide tape depending upon the situation in which the “field” or turf will be used. Typically, in this method, the glue takes a full 24 hours to cure all the way through and the process of gluing down the mesh under existing methods is extremely labor intensive. The adhesive used must be notch trowelled on to the mesh to ensure an even coating of the glue across the entire tape. There are several drawbacks to using the prior art methods.
The adhesive used in these methods is either a synthetic, rubber, or other chemical makeup. There are petroleum distillates in many of them and the chemicals may cause problems and produce hazardous side effects. Typically, artificial turf heats up to 3 times the temperature of sod. When this happens, the chemicals in the adhesive can “gas”. This not only causes the seam to rise up and “peak” off of the substrate or supporting surface, but also releases harsh vapors. If there is too much glue or adhesive applied to the seam, the chemicals in the adhesives can eat away at or dissolve the rubber backings of the turf itself when the field is heated up by the outdoor sun.
What is needed is a carpet or artificial turf seaming method that is suited for use in applications where the backing on the carpet or artificial turf is particularly dense or thick, and also where the seam should be both waterproof and wear resistant without creating a “hump” or profile in the carpet seam.
The carpet seaming apparatus of the present invention provides a durable seam in both commercial carpet and artificial turf applications. The seam secured by the seaming apparatus is both more secure and more durable than those in the prior art. The tape used in the seaming apparatus is waterproof to provide wear resistance in both outdoor and high traffic, frequently cleaned indoor applications. Furthermore, in the event of seam failure, a smaller area of carpet or turf would need to be removed or replaced due to the narrow profile of the seaming apparatus.
The carpet seaming apparatus of the present invention may use as its main adhesive layer a pressure sensitive butyl rubber tape. Butyl rubber is an inert substance and will not gas. Because of its natural state, butyl rubber tape stays pliable to extreme hot and cold temperatures. The metal “plate” of our product ensures that the seam will not “peak” and the teeth hold the backings in place. Typically seam failure is the primary cause of turf failure and the average cost of fixing a seam is $5000.00. There are typically 30-40 seams in a conventional artificial turf football field installation. Therefore there are many potential costly points of failure in an artificial turf installation using the mesh seam method. Expensive seam repairs will not be required using the seaming apparatus and method of the present invention.
The carpet seaming apparatus of the present invention is formed from an elongated plate that is inextendible in both longitudinal and lateral directions. In the preferred embodiment, a thin metal plate is utilized, however, the plate could be formed from rigid plastic. The plate has a lower surface that may also have a thin pressure sensitive adhesive layer which enables the plate to be readily secured upon a supporting surface. An upper surface of the plate is divided into multiple, transversely spaced, and longitudinally extending zones. In the preferred embodiment, three such zones, including two edge zones spaced by a central zone, are provided. Numerous elongated upstanding sharp projections are provided in each of the edge zones and a double-sided adhesive tape is provided in the central zone. A peelable protective cover is arranged atop the pressure sensitive adhesive tape. For indoor/interior applications of the invention a pressure sensitive fiber tape that is “water resistant” may be used. For indoor applications that will be frequently cleaned with steam or exposed to water or for outdoor/exterior applications, a completely waterproof pressure sensitive butyl rubber tape will be used.
In a first embodiment of the invention, the plate may be cut in length to correspond to the width dimension of the carpet sections to be seamed. The carpet padding, carpet, or artificial turf are arranged to the surface on which they are placed, and terminal edge portions of the carpet sections to be seamed are attached to the plate through the projections and the adhesive tape. The elongated projections in the edge zones of the plate extend into the carpet or turf, and the adhesive tape further secures the backing of the carpet or turf to the seaming apparatus. The seaming apparatus may be either glued in place with hot melt tape or secured with a pressure sensitive fiber tape. In another embodiment, the seaming apparatus may have no adhesive or securing layer on the back of the seaming apparatus.
In another embodiment, the plate of the present invention may have a double sided pressure sensitive fiber tape on the back or bottom of the plate and a waterproof pressure sensitive butyl rubber tape in the center portion of the top side of the plate. A carpet padding or other padding is first glued to a supporting surface, and the underside of the carpet or artificial turf, except for the area around the seams, is glued to the carpet padding. The area around the seam may be a 3 inch wide strip of the underside of the carpet or artificial turf. The plate is then installed in the seam by removing a covering on the double sided pressure sensitive fiber tape on the bottom of the plate, and the underside of the carpet or artificial turf is secured to the elongated projections of the edge zones and to the pressure sensitive butyl rubber tape on the top of the seaming apparatus. In this embodiment, the center zone of the plate may be proportionally larger than each of the edge zones of the plate.
In another embodiment the present invention provides a seaming apparatus comprising: an elongated plate having an upper surface and a lower surface, said lower surface being substantially smooth and said upper surface being divided into multiple transversely spaced and longitudinally extending zones including first and second edge zones which are laterally spaced by a central zone, said plate being inextendible in both longitudinal and lateral directions; a plurality of sharp, elongated projections extending upwardly at spaced locations from said first and second edge zones, said projections having a top and an elongated body portion, the top being sharply tapered to promote piercing engagement with a floor covering backing and the elongated body extending upwards from the upper surface at an angle of less than 90 degrees; and a pressure sensitive adhesive layer positioned within said central zone and extending substantially entirely the length of said elongated plate, said plate being adapted to be positioned upon a supporting surface and interconnected to floor covering sections to be seamed by positioning said plate below said floor covering sections with terminal edge portions of said floor covering sections being fixably engaged with said adhesive layer and with a respective set of said projections and abutting in said central zone.
In another embodiment the present invention provides a method of seaming two floor covering sections comprising: arranging edge portions of the floor covering sections juxtaposed one another upon a support surface; positioning an elongated, inextendible plate upon the support surface, the lower surface of said plate directly contacting the support surface below the respective edge portions of said floor covering sections, the plate having a substantially smooth lower surface, an upper surface provided with first and second longitudinally extending edge zones having a plurality of sharp, elongated projections extending upwardly at spaced locations from said first and second edge zones, said projections having a top and an elongated body portion, the top being sharply tapered to promote piercing engagement with a floor covering backing and the elongated body extending upwards from the upper surface at an angle of less than 90 degrees, and a central, adhesive containing zone extending substantially entirely the length of said elongated plate; and interengaging the edge portion of one of the floor covering sections with the projections provided in said first edge zones and interengaging the edge portion of the other of the floor covering sections with the projections provided in said second edge zone while adhesively joining the edge portions of the carpet sections together in an abutting manner in said central zone.
In another embodiment the present invention provides a carpet seaming apparatus comprising: an elongated plate having an upper surface and a lower surface, said lower surface being substantially smooth and said upper surface being divided into multiple transversely spaced and longitudinally extending zones including first and second edge zones which are laterally spaced by a central zone, said plate being inextendible in both longitudinal and lateral directions; a plurality of sharp, elongated projections extending upwardly at spaced locations from said first and second edge zones; and a pressure sensitive adhesive layer positioned within said central zone and extending substantially entirely the length of said elongated plate, said plate being adapted to be positioned upon a supporting surface and interconnected to carpet sections to be seamed by positioning said plate below said carpet sections with terminal edge portions of said carpet sections being engaged with a respective set of said projections and abutting in said central zone.
This carpet seaming embodiment of the present invention may also have projections located solely in said first and second edge zones. The lower surface of the apparatus may have a thin adhesive layer. The adhesive layer may be located solely in said central zone, and may be a pressure sensitive butyl rubber tape or a pressure sensitive fiber tape. The plate may be formed of metal and the projections may be constituted by cut portions of said plate which are bent upwardly above said upper surface. The projections may be angled toward said central zone, and may be angled toward the central zone at an angle of 70 degrees from the upper surface. The projections may be 8 mm in length from an attached proximal end to a projecting distal end, or may be 5.5 mm in length from an attached proximal end to a projecting distal end. The projections may be arranged in three or four columns in each of said edge zones. The projections may be arranged in offset rows in each of said edge zones, said rows having one, two, three, or four projections in each row. The adhesive layer may comprise a double-sided pressure sensitive adhesive tape having a lower side adhered to said central zone and an upper side adapted to be adhesively secured to the carpet sections, and may have a protective, peelable cover positioned atop said adhesive tape. The central zone may comprise greater than 33.3% of the width of the plate. The central zone and edge zones may each comprise 33.3% of the width of the plate.
In another embodiment, the present invention provides a method for seaming a carpet comprising: gluing down a padding layer and a carpet layer, said glued carpet and padding layers having a seam comprising a first and second terminal end; placing a seaming apparatus by removing a peelable backing from a thin lower adhesive layer in said seam, said seaming apparatus comprising an elongated plate having an upper surface and a lower surface, said lower surface being substantially smooth and having the thin lower adhesive layer positioned thereon, and said upper surface being divided into multiple transversely spaced and longitudinally extending zones including first and second edge zones which are laterally spaced by a central zone, said plate being inextendible in both longitudinal and lateral directions; a plurality of sharp, elongated projections extending upwardly at spaced locations from said first and second edge zones; and a pressure sensitive adhesive layer positioned within said central zone and extending substantially entirely the length of said elongated plate; and securing said first and second terminal ends to said pressure sensitive adhesive layer and engaging said first and second terminal ends to said plurality of projections.
In yet another embodiment, the present invention provides a method for seaming a carpet comprising: gluing down a padding layer and a carpet layer, said glued carpet and padding layers having a seam comprising a first and second terminal end; placing a seaming apparatus in said seam, said seaming apparatus comprising an elongated plate having an upper surface and a lower surface, said lower surface being substantially smooth, and said upper surface being divided into multiple transversely spaced and longitudinally extending zones including first and second edge zones which are laterally spaced by a central zone, said plate being inextendible in both longitudinal and lateral directions; a plurality of sharp, elongated projections extending upwardly at spaced locations from said first and second edge zones; and a pressure sensitive adhesive layer positioned within said central zone and extending substantially entirely the length of said elongated plate; and securing said first and second terminal ends to said pressure sensitive adhesive layer and engaging said first and second terminal ends to said plurality of projections.
Additional features and advantages of the carpet seaming apparatus of the present invention will become more readily apparent from the following detailed description of the preferred embodiment thereof, when taken in conjunction with the drawings wherein like reference numerals refer to corresponding parts in the several views.
In order to facilitate a full understanding of the present invention, reference is now made to the accompanying drawings, in which like elements are referenced with like numerals. These drawings should not be construed as limiting the present invention, but are intended to be exemplary and for reference.
The present invention will now be described in more detail with reference to exemplary embodiments as shown in the accompanying drawings. While the present invention is described herein with reference to the exemplary embodiments, it should be understood that the present invention is not limited to such exemplary embodiments. Those possessing ordinary skill in the art and having access to the teachings herein will recognize additional implementations, modifications, and embodiments, as well as other applications for use of the invention, which are fully contemplated herein as within the scope of the present invention as disclosed and claimed herein, and with respect to which the present invention could be of significant utility.
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The upper surface of plate 202 is divided into three zones. The adhesive zone 220 and edge zones 210 and 212 generally define strips that run the full length of plate 202. In a preferred embodiment, the central adhesive zone 220 is 63.5 mm in width and both edge, or “tooth”, zones 210 and 212 are 44.45 mm in width.
Positioned on the upper surface of the plate 202 and within the central adhesive zone 220 is a strip of adhesive. In indoor implementations of the present invention, a pressure sensitive adhesive with fiber glass fibers intertwined will be used. This type of adhesive may be a pressure sensitive fiber type. In outdoor implementations of the present invention, a pressure sensitive butyl rubber tape will be used. Using a butyl rubber tape in outdoor implementations is preferred due to the water resistant qualities of the butyl rubber tape. Using glues or adhesives other than a rubber tape in outdoor implementations may weaken the seam and cause seam failure over time. In either indoor or outdoor implementations, a peelable protective cover may be placed on top of the strip of adhesive in the central adhesive zone 220. Although preferred embodiments of the invention use a form of adhesive tape, it should be readily understood that other types of arrangements could be utilized to provide a layer of adhesive in the central adhesive zone 220.
The use of the seaming apparatus 200 is a great improvement over seaming methods for artificial turf in the prior art. Currently, the preferred method for seaming artificial turf in the prior art comprises using a 30 inch wide mesh with gallons of rubber based adhesive “troweled” onto the mesh to secure the seam. Troweling is spreading glue in a pattern that scrapes away glue in rows so that the glue can flatten out. If this type of seam fails, 30 inches of artificial turf must be cut out and replaced which may be very costly. Using the seaming apparatus of the present invention, the seam will both be stronger and a smaller amount of artificial turf would have to be replaced in the event of seam failure.
In each of the edge zones 210 and 212, a plurality of sharp upstanding projections arranged in rows and columns are provided throughout the surface of the edge zones 210 and 212. The specific arrangement of the plurality of upstanding projections is illustrated in greater detail in
With reference now to
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The upper surface of plate 602 is divided into three zones. The adhesive zone 620 and edge zones 610 and 612 generally define strips that run the full length of plate 602. In a preferred embodiment, the central adhesive zone 620 is 36.5 mm in width, or 41.6% of the width, and both edge, or “tooth”, zones 610 and 612 are 19.85 mm in width, or a total of 58.4% of the width.
Positioned on the upper surface of the plate 602 and within the central adhesive zone 620 is a strip of adhesive. In a preferred embodiment of the present invention, a pressure sensitive butyl rubber tape will be used. Using a butyl rubber tape in indoor implementations is preferred due to the water resistant qualities of the butyl rubber tape. Water resistance is desired due to the frequent cleaning that a high traffic carpet may require. Using glues or adhesives other than a rubber tape in this indoor implementation may weaken the seam and cause seam failure over time. A peelable silicon protective cover may be placed on top of the strip of adhesive in the central adhesive zone 620. Although preferred embodiments of the invention use a form of adhesive tape, it should be readily understood that other types of arrangements could be utilized to provide a layer of adhesive in the central adhesive zone 620.
In each of the edge zones 610 and 612, a plurality of sharp upstanding projections arranged in rows and columns are provided throughout the surface of the edge zones 610 and 612. The specific arrangement of the plurality of upstanding projections is illustrated in greater detail in
With reference now to
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The upper surface of plate 1202 is divided into three zones. The adhesive zone 1220 and edge zones 1210 and 1212 generally define strips that run the full length of plate 602. In a preferred embodiment, the central adhesive zone 1220 is 36.5 mm in width, or 41.6% of the width, and both edge, or “tooth”, zones 1210 and 1212 are 19.85 mm in width, or a total of 58.4% of the width.
Positioned on the upper surface of the plate 1202 and within the central adhesive zone 1220 is a strip of adhesive. In a preferred embodiment of the present invention, a pressure sensitive butyl rubber tape will be used. A peelable silicon protective cover may be placed on top of the strip of adhesive in the central adhesive zone 1220. Although preferred embodiments of the invention use a form of adhesive tape, it should be readily understood that other types of arrangements could be utilized to provide a layer of adhesive in the central adhesive zone 1220.
In each of the edge zones 1210 and 1212, a plurality of sharp upstanding projections arranged in rows and columns are provided throughout the surface of the edge zones 1210 and 1212. The specific arrangement of the plurality of upstanding projections is illustrated in greater detail in
With reference now to
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Furthermore, with respect to the carpet seaming apparatus provided in
From the above description, it should be readily apparent that an efficient and effective seaming arrangement is provided by the present invention which will eliminate seam failure problems in both artificial turf and commercial carpet applications.
While the invention has been described by reference to certain preferred embodiments, it should be understood that numerous changes could be made within the spirit and scope of the inventive concept described. Also, the present invention is not to be limited in scope by the specific embodiments described herein. It is fully contemplated that other various embodiments of and modifications to the present invention, in addition to those described herein, will become apparent to those of ordinary skill in the art from the foregoing description and accompanying drawings. Thus, such other embodiments and modifications are intended to fall within the scope of the following appended claims. Further, although the present invention has been described herein in the context of particular embodiments and implementations and applications and in particular environments, those of ordinary skill in the art will appreciate that its usefulness is not limited thereto and that the present invention can be beneficially applied in any number of ways and environments for any number of purposes. Accordingly, the claims set forth below should be construed in view of the full breadth and spirit of the present invention as disclosed herein.
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| Number | Date | Country | |
|---|---|---|---|
| 20150366390 A1 | Dec 2015 | US |
