Cushioned backed carpet tile with stabilized nonwoven backing

• US 5,540,968 A
• Filed: 09/27/1994
• Issued: 07/30/1996
• Est. Priority Date: 03/03/1994
• Status: Expired due to Term

• Current Assignee: Milliken & Company
• Original Assignee: Milliken Research Corporation
• Inventors: Higgins, Kenneth B.
• Primary Examiner(s): MORRIS, TERREL H
• Application Number:
  US08/312,817
• Time in Patent Office: 672 Days
• Field of Search: 428/95, 428/288, 428/296, 156/72
• US Class Current: 428/95
• CPC Class Codes: D06N 2201/02 Synthetic macromolecular fibres
• CPC Class Codes: D06N 2201/0254 Polyolefin fibres
• CPC Class Codes: D06N 2201/0263 Polyamide fibres
• CPC Class Codes: D06N 2203/066 Silicon polymers
• CPC Class Codes: D06N 2203/068 Polyurethanes
• CPC Class Codes: D06N 2205/06 Melt
• CPC Class Codes: D06N 2205/20 Cured materials, e.g. vulcanised, cross-linked
• CPC Class Codes: D06N 3/14 with polyurethanes
• CPC Class Codes: D06N 7/0068 characterised by the primary backing or the fibrous top layer
• CPC Class Codes: D06N 7/0073 the back coating or pre-coat being applied as an aqueous dispersion or latex
• CPC Class Codes: D06N 7/0078 the back coating or pre-coat being applied as a hot melt
• 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: D06N 7/0086 characterised by the cushion backing, e.g. foamed polyurethane
• CPC Class Codes: Y10T 156/1084 of continuous or running length bonded web
• CPC Class Codes: Y10T 428/23979 Particular backing structure or composition
• CPC Class Codes: Y10T 428/23986 With coating, impregnation, or bond
• CPC Class Codes: Y10T 428/23993 Composition of pile or adhesive

Abstract

A cushioned carpet tile is provided. The cushioned carpet tile includes a primary carpet fabric having a plurality of pile-forming yarns projecting from one side thereof. A mass of polymer cushioning is dispersed on the side of the primary carpet fabric from which the pile-forming yarns do not extend. A heat-fused nonwoven backing of polyester and polypropylene is disposed on the bottom of the polymer cushioning. The ratio of polyester to polypropylene in the nonwoven backing is between about 0.43 and about 2.3.

Claims

1. A carpet tile, comprising:

a primary carpet fabric having a plurality of pile-forming yarns projecting outwardly therefrom;

a mass of foamed polymer cushioning disposed on a side of said primary carpet fabric away from said plurality of pile-forming yarns; and

a nonwoven backing comprising a heat-fused composite of polyester and polypropylene wherein the ratio of polyester to polypropylene is between about 0.43 and about 2.3.

2. The invention as in claim 1, wherein the ratio of polyester to polypropylene is between about 0.67 and about 1.5.

3. The invention as in claim 1, wherein the nonwoven backing consists essentially of about 50 percent polypropylene and about 50 percent polyester.

4. The invention as in claim 1, further including a layer of reinforcement material bonded to the underside of said primary carpet fabric.

5. The invention as in claim 4, wherein said reinforcement material comprises nonwoven fiberglass.

6. A carpet tile, comprising:

a primary carpet fabric having a plurality of pile-forming yarns projecting outwardly therefrom;

a mass of foamed polymer cushioning disposed on a side of said primary carpet fabric away from said plurality of pile forming yarns; and

a nonwoven backing layer in direct contacting relation with said mass of polymer cushioning, said nonwoven backing layer comprising a heat fused composite of polyester and polypropylene wherein the ratio of polyester to polypropylene in the nonwoven backing layer is between about 0.43 and about 2.3.

7. The invention as in claim 6, wherein the ratio of polyester to polypropylene in the nonwoven backing layer is between about 0.67 and about 1.5.

8. The invention as in claim 6, wherein the nonwoven backing layer consists essentially of about 50 percent polypropylene and about 50 percent polyester.

9. The invention as in claim 6, further including a layer of reinforcement material bonded to the underside of said primary carpet fabric.

10. The invention as in claim 9, wherein said reinforcement material comprises nonwoven fiberglass.

11. A carpet tile, comprising:

a primary carpet fabric having a plurality of pile-forming yarns projecting outwardly therefrom;

a mass of heat cured foamed polyurethane cushioning disposed on a side of said primary carpet fabric away from said plurality of pile forming yarns; and

a nonwoven backing layer in direct contacting relation with said mass of polyurethane cushioning, said nonwoven backing layer comprising a heat fused composite of polyester and polypropylene wherein the ratio of polyester to polypropylene in the nonwoven backing layer is between about 0.43 and about 2.3.

12. The invention as in claim 11, wherein the ratio of polyester to polypropylene in the nonwoven backing layer is between about 0.67 and about 1.5.

13. The invention as in claim 11, wherein the nonwoven backing layer consists essentially of about 50 percent polypropylene and about 50 percent polyester.

14. The invention as in claim 11, further including a layer of reinforcement material bonded to the underside of said primary carpet fabric.