Lay Flat Flooring Products and Methods

• US 20090029096A1
• Filed: 12/21/2006
• Published: 01/29/2009
• Est. Priority Date: 12/21/2005
• Status: Abandoned Application

• Current Assignee: Dennis L. Riddle
• Original Assignee: Dennis L. Riddle
• Inventors: Riddle, Dennis L.
• Application Number:
  US12/096,138
• Publication Number:
  US 20090029096A1
• Time in Patent Office: Days
• US Class Current: 428/95
• CPC Class Codes: B32B 2038/0076 Curing, vulcanising, cross-linking
• CPC Class Codes: B32B 2471/00 Floor coverings B32B2419/04 takes precedence
• CPC Class Codes: B32B 5/02 characterised by structural features of a fibrous or filamentary layer layer formed of metallic wires B32B15/02; layer formed of natural mineral fibres B32B19/02; layer formed of wood fibres B32B21/02
• CPC Class Codes: B32B 5/26 another layer next to it also being fibrous or filamentary relative arrangement of fibres or filaments of different layers B32B5/12
• CPC Class Codes: D06N 2203/042 Polyolefin (co)polymers
• CPC Class Codes: D06N 2203/061 Polyesters
• CPC Class Codes: D06N 2203/065 Polyamides
• CPC Class Codes: D06N 2205/106 Scrap or recycled particles
• CPC Class Codes: D06N 2205/18 Scraps or recycled materials D06N2205/106 takes precedence
• CPC Class Codes: D06N 7/0068 characterised by the primary backing or the fibrous top layer
• CPC Class Codes: D06N 7/0081 with at least one extra fibrous layer at the backing, e.g. stabilizing fibrous layer, fibrous secondary backing
• CPC Class Codes: Y02P 70/62 related technologies for production or treatment of textile or flexible materials or products thereof, including footwear
• CPC Class Codes: Y10T 428/23979 Particular backing structure or composition
• CPC Class Codes: Y10T 428/24802 Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
• CPC Class Codes: Y10T 428/26 Web or sheet containing structurally defined element or component, the element or component having a specified physical dimension
• CPC Class Codes: Y10T 442/30 Woven fabric [i.e., woven strand or strip material]
• CPC Class Codes: Y10T 442/40 Knit fabric [i.e., knit strand or strip material]
• CPC Class Codes: Y10T 442/682 Needled nonwoven fabric

Abstract

A surface covering such as a lay flat flooring product having an upper show surface disposed in overlying relation to a single or multi-layer, preferably flexible, heavy, thin, resilient backing. A fibrous backing sheet may be disposed across an underside of the backing. The surface covering may be, for example, a tile or roll goods. The show surface may be a decorative textile or carpet layer.

Claims

1. A lay flat flooring product comprising an upper show surface disposed in overlying relation to a single or multi-layer, flexible, heavy, thin backing, said backing having at least one of a bending modulus of less than about 3,000 psi, a thickness of less than about 15 mm, and a density of greater than about 15 lbs/ft³.

2. The invention of claim 1, further comprising a flexible fibrous backing sheet disposed at a position below an underside of the backing.

3. The invention of claim 1, wherein the flooring product is one of a tile and roll goods.

4. The invention of claim 1, wherein the show surface is one of a decorative textile and a carpet layer.

5. The invention of claim 4, wherein the show surface is formed of a material selected from polyester, polyamide (Nylon), polyolefin, blends, and combinations thereof.

6. The invention of claim 4, wherein the show surface is one of knit, woven, tufted, bonded, nonwoven, needled, flocked, graphics tufted, printed, dyed, and combinations thereof.

7. The invention of claim 1, wherein the backing is at least one of resilient, flexible, and formed of polyurethane.

8. The invention of claim 1, wherein the show surface is disposed in overlying relation to a multi-layer backing.

9. The invention of claim 8, wherein the backing includes at least one stabilizing layer.

10. The invention of claim 9, wherein said stabilizing layer is at least one of woven or nonwoven glass.

11. The invention of claim 1, wherein said backing has a bending modulus of less than about 3,000 psi, a thickness of less than about 15 mm, and a density of greater than about 15 lbs/ft³.

12. The invention of claim 1, wherein said backing has a bending modulus of less than about 2,000 psi, a thickness of less than about 10 mm, and a density of greater than about 20 lbs/ft³.

13. The invention of claim 1, wherein said backing has a bending modulus of less than about 1,000 psi, a thickness of less than about 5 mm, and a density of greater than about 50 lbs/ft³.

14. A method of producing a lay flat flooring product such as a lay flat tile or roll goods product with a carpet or textile face and a flexible, heavy, thin, resilient backing, comprising the steps of:

preparing a backing composition;

depositing the backing composition in a layer;

placing a carpet or textile face material on the deposited backing layer to form a multi-layer structure;

setting or curing the backing so that the backing composition forms a flexible, heavy, thin, resilient backing, and wherein the carpet or textile face material is bonded to the backing.

15. The method of claim 14, wherein the carpet or textile face material is at least one of knit, woven, tufted, bonded, nonwoven, needled, flocked, graphics tufted, printed, dyed, and combinations thereof.

16. The method of claim 14, further comprising the step of adding one or more additional layers in, over or under the backing composition layer.

21. The method of claim 14, wherein the backing composition is a polyurethane.

23. A lay flat flooring product produced by the method of claim 14.

17. A method of producing a lay flat flooring product such as a lay flat tile or roll goods product with a carpet or textile face and a flexible, heavy, thin, resilient backing, comprising the steps of:

preparing a backing composition;

inverting a carpet or textile face material;

depositing the backing composition on the inverted face material to form a multi-layer structure;

setting or curing the backing so that the backing composition forms a flexible, heavy, thin, resilient backing, and wherein the carpet or textile face material is bonded to the backing.

18. The method of claim 17, wherein the carpet or textile face material is at least one of knit, woven, tufted, bonded, nonwoven, needled, flocked, graphics tufted, printed, dyed, and combinations thereof.

19. The method of claim 17, further comprising the step of adding one or more additional layers in, over or under the backing composition layer.

22. The method of claim 17, wherein the backing composition is a polyurethane.

24. A lay flat flooring product produced by the method of claim 17.

20. (canceled)