Flooring system and method

a technology of floor covering and floor covering, applied in the direction of carpet fasteners, other domestic articles, synthetic resin layered products, etc., can solve the problems of affecting the performance of carpeting, affecting and causing many problems, so as to facilitate the cooperative arrangement of elements, facilitate installation, and obscure the appearance of seams

Inactive Publication Date: 2004-02-05
MILLIKEN & CO
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

[0011] According to another aspect of the invention, a method is provided for forming a residential modular carpet and carpet tile having resilience, under foot comfort, the look and feel of broadloom carpet, seamless appearance when installed, which is easy to install, can be installed by the homeowner, and has performance characteristics that rate it for residential or home use.

Problems solved by technology

Too much cushioning in a commercial carpet tile is detrimental to the performance.
The ledge creates many problems.
In severe cases the separation can be a tripping hazard.
Further, Applicants are unaware of any modular carpeting product which has fully satisfied the needs of adequate cushioning, plush pile, and minimal edge displacement, and is durable with use relevant to a residential installation.

Method used

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  • Flooring system and method

Examples

Experimental program
Comparison scheme
Effect test

examples 1-5

[0114] The following examples set forth production specifications or overall floor covering composite constructions

example 1

[0115]

12Example 1 (A) (B) 1. Product Type Residential Modular Floor Covering 2. Face: High Twist Frieze Cut pile 3. Primary Backing: Woven polypropylene (PolyBac - 4 oz / yd.sup.2) 4. Total Finished 38 oz / yd.sup.2 Yarn Weight: 5. Stitches Per Inch: 7.81 6. Tufting Gauge: 1 / 8 7. Yarn Polymer: Nylon 6,6 8. Yarn Type: 1180 filament, with antistat, semi dull trilobal, 17 dpf 9. Yarn Twist: 7.50 twist per inch in singles (S) and ply (Z) 10. Yarn Ply: 2 ply twisted 11. Heatset: Yes, @ 260 to 264.degree. F. with steam frieze 12. Yarn Size: 3.69 / 2 cotton count 13. Tufted Pile Height: 48 / 64 inches (3 / 4") 14. Dyeing Method Jet Dye 15. Precoat Adhesive: Styrene Butadiene Latex, 12 oz / yd.sup.2 coating weight 16. Lamination Hotmelt with a bitumen and polypropylene resin base, Tiecoat Adhesive: 17. Upper Tiecoat 46 oz / yd.sup.2 Coating Weight: 18. Stabilizing Fiberglass Mat, 2 oz / yd.sup.2, modified acrylic Reinforcement: binder 19. Lower Tiecoat 15 oz / yd.sup.2 Coating Weight: 20. Cushion Type: Rebon...

example 2

[0116]

13 (A) (B) 1. Product Type Residential Modular Floor Covering 2. Face: High Twist Frieze Cut pile 3. Primary Backing: Woven polypropylene (PolyBac - 4 oz / yd.sup.2) 4. Total Finished 38 oz / yd.sup.2 Yarn Weight: 5. Stitches Per Inch: 7.81 6. Tufting Gauge: 1 / 8 7. Yarn Polymer: Nylon 6,6 8. Yarn Type: 1180 filament, with antistat, semi dull trilobal, 17 dpf 9. Yarn Twist: 7.50 twist per inch in singles (S) and ply (Z) 10. Yarn Ply: 2 ply twisted 11. Heatset: Yes, @ 260 to 264.degree. F. with steam frieze 12. Yarn Size: 3.69 / 2 cotton count 13. Tufted Pile Height: 48 / 64 inches (3 / 4") 14. Dyeing Method Jet Dye, 15. Precoat Adhesive: Styrene Butadiene Latex, 12 oz / yd.sup.2 coating weight 16. Lamination Hotmelt with a bitumen and Tiecoat Adhesive: polypropylene resin base, 17. Upper Tiecoat 46 oz / yd.sup.2 Coating Weight: 18. Stabilizing Fiberglass Mat, 2 oz / yd.sup.2, modified Reinforcement: acrylic binder 19. Lower Tiecoat 15 oz / yd.sup.2 Coating Weight: 20. Cushion Type: Rebond polyur...

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Abstract

A flooring system for use in a residential environment. The flooring system includes a subfloor adapted to support the mass of a user and modular surface covering elements for disposition in edge to edge covering arrangement across at least a portion of the subfloor. The modular surface covering elements include a pile fabric face with an arrangement of yarns projecting outwardly defining a pile layer for contact by a user. At least one layer of cushioning material is disposed in contacting relation at a position below the pile fabric face.

Description

[0001] The present invention relates to flooring systems and more particularly to flooring systems incorporating a multiplicity of replaceable modular surface covering elements adapted for installation in a coordinated arrangement across a supporting subfloor. Constructions of modular surface coverings and methods of formation and installation are also provided.[0002] Cushion back carpet products or carpet tiles are described for example in U.S. Pat. Nos. 4,522,857 and 6,203,881 each hereby incorporated by reference herein.[0003] The evolution of flooring in the commercial and residential markets has progressed in two distinct directions based substantially on the requirements of the end user. One aspect of the evolution of commercial floor coverings has been directed to modular floor coverings. The commercial market is exemplified by high traffic, both foot traffic and rolling equipment, and minimal demand for plush, high, pile. A particular problem with commercial applications is ...

Claims

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Application Information

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IPC IPC(8): A47G27/02A47G27/04B32B5/18B32B5/24B32B27/12D06N7/00E04F15/16
CPCA47G27/0293Y10T428/164B32B5/18B32B5/22B32B5/24B32B27/12E04F15/16E04F2201/091E04F2201/096D06N7/0073D06N2203/042D06N7/0078D06N7/0065D06N2209/1671D06N2203/065D06N2209/0807D06N7/0084D06N7/0076Y10T428/163Y10T428/16Y10T428/168A47G27/0475Y10T428/23957Y10T428/23979Y10T428/23907Y10T428/23929B32B3/02B32B2262/0253B32B5/245B32B5/26B32B2471/02B32B25/10B32B25/12
Inventor HIGGINS, KENNETH B.HAYES, HEATHER J.LI, SHULONGGODFREY, THOMAS E.SELLMAN, N. DAVID JR.BROWN, ROBERT S.TIPPETT, WILLIAM
Owner MILLIKEN & CO
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