KR20030051874A - Textile product and method - Google Patents

Abstract

The invention incorporates a stabilizing material layer 158 and an adhesive material layer 160 under a first carpet 112 and above a layer 178 of compressed particles, regenerated and / or recombining foam or cushioning material in one embodiment. To a layered cushion composite such as carpet or carpet tiles.

Description

Textile products and manufacturing method thereof {TEXTILE PRODUCT AND METHOD}

All of the US patents mentioned herein are incorporated herein by reference.

US Pat. Nos. 4,522,857, 5,540,968, 5,545,276, 5,948,500 and 6,203,881, all of which are incorporated herein by reference, describe carpet or carpet tiles with cushion backing. As described in US Pat. No. 5,948,500 and presented herein, an example of a tufted carpet product 10A is shown in FIG. 1A and an example of a bonded carpet product 10B is shown in FIG. 1B.

In the tuft carpet 10A of FIG. 1A, the first carpet fabric 12 is bonded to an adhesive layer 16 containing a glass scrim layer 18. The foam base composite 19 is bonded to the adhesive layer 16 in this manner with an adhesive. In such tufted carpet structures, the first carpet fabric 12 may pass through a tuft loop pile layer 20 passing through the first backing 22 (eg, nonwoven textile) by conventional tufting methods. And is fixed in place by a pre-coat backing layer 24 of latex or other suitable adhesive. The foam base composite 19 of the tufted carpet product 10A includes an intermediate layer 26 molded into the urethane foam layer 28 as shown.

The bonded carpet product 10B of FIG. 1B uses the same type of foam base composite 19 bonded with adhesive by an adhesive laminate layer 16 disposed on a glass scrim layer 18. However, the first bonded carpet fabric 12 has a cutting pile yarn 34 infused into an adhesive 36 (e.g. PVC, latex or hot melt adhesive), and with fiberglass, nylon, polypropylene or polyester It has a slightly different component than that of the tufted product 10A in that it has a woven- or nonwoven-reinforced or substrate layer 38 of the same material.

In the process of forming the foam base composite 19 for use in conventional cushion carpet structures in tufted or bonded form, U.S. Pat. No. 4,171,395 to Tilotson, which is typically incorporated herein by reference Implementation practices as disclosed in US Pat. Nos. 4,132,817 and 4,512,831 have included pre-forming and curing virgin urethane foams across a carrier or backing material. As described in these patents, such foam base composites are laminated to a carpet base, thereby obtaining a cushion structure.

As described in the aforementioned patent 5,948,500, the costs associated with this module formation and assembly implementation practice are such that the first carpet fabric is laminated directly to the polyurethane-forming composition with or without a stabilizing layer such as scrim. Then, it can be saved by a simple operation of curing the polyurethane. The method may be more effective if the polyurethane-forming composition does not require any pre-cure before bonding the carpet base.

In known methods for applying polyurepan-cushion backing to fabric substrates, known prior to the invention described in patent 5,948,500, both the polyurethane composition and the bonding fabric layer are laminated by first carpet It was dependent on very close temperature control to be stabilized by pre-curing the polyurethane before forming the structure. Such pre-cure has been thought to be highly necessary to obtain a stable foam structure to which the first carpet backing is applied. Heating the polyurethane composition prior to the joiner of the heating fabric backing allowed the polymer crosslinking, which is believed to be necessary to stabilize the foam mixture to a degree sufficient to prevent collapse of the foam.

The invention described in patent 5,948,500 also provides a particularly simple composite structure which is compliant with the formation of in situ systems of stable cushion carpet composites. In particular, by laminating the first carpet fabric to some extent with or without preheating, all the cushion carpet composite layers are transferred together directly to a mechanically foamed polyurethane-forming composition free of interlayer material prior to curing of the polyurethane. A single process is used.

As described in patent 5,948,500, the base of the first carpet fabric is adhesively bonded to the nonwoven glass reinforcement material layer to form a preliminary composite. The polyurethane-forming composition puddle is deposited simultaneously across the woven or nonwoven backing material. Almost immediately thereafter, the precomposite and the polyurethane-forming composition together are laminated to and supported by the pre-composite in the polyurethane-forming puddle. The whole structure is then heated to cure the polyurethane-forming composition. The preliminary composite may be slightly heated to about 120 ° F., although the process may be performed without this pre-heating, the thermal efficiency may be improved.

Superior cushion backing carpet tiles or modular cushion bags currently on the market, such as those sold under the trade name Comfort Plus® by Milliken & Company, LaGrange, GA. (back) carpet tile is about 20 to about 40oz / surface weight of yd ^2, from about 38 to about 54oz / hot-melt layer of yd ^2, from about 0.10 to 0.2 inch thick cushion, about 28 to a 34oz / yd ² cushioned by weight, And a first carpet fabric having a cushion density of about 18 lbs / ft ³ and a product overall height of about 0.4 to 0.8 inches.

This superior cushion bag carpet tile offers excellent resilience and under foot comfort, exhibits performance characteristics that are valued for commercial scale mass use, and offers excellent appearance, feel, wear resistance, and comfort throughout the industry. And significant states such as having cushion characteristics, performance, properties, and the like have been achieved. In such cushioning backing carpet tiles, the production costs are relatively high due to the high quality and quantity of materials used.

Attempts have been made to reduce the cost of floor coverings or carpets using low quality materials, but these attempts have not been particularly successful. Low quality products tend to fall short of expectations in terms of appearance, feel, wear resistance, comfort and cushioning. Therefore, these products have not been accepted in industry and have failed commercially.

One of the success stories of relatively low cost floor coverings, carpet or carpet tiles, and methods of making such products is described in US patent application Ser. No. 09 / 587,654, which is incorporated herein by reference. Patent application 09 / 587,654 describes a method for producing a low weight composite structure that is compliant with in situ formation as a stable cushion carpet composite. In one embodiment of such a low weight cushion carpet composite, a low surface weight first carpet fabric having a tuft or bonded structure, which is adhesively bonded to the reinforcing material layer, is incorporated to form the preliminary composite. This preliminary composite is then laminated into a polyurethane-forming material puddle. The resulting structure was then heated to cure the polyurethane-forming material to yield a cushion structure.

Summary of the Invention

In one or more embodiments of the present invention, a relatively low cost, environmentally friendly and aesthetically superior, preferably incorporating a layer of compressible particles bonded to each other, such as recombination foam or other compressed particle foam, incorporating a cushion or foam material. By providing laminated cushioned textile products, composites or structures that are stable and / or wear resistant, advantages and / or alternatives are provided that are superior to conventional textile products, composites or structures, such as surface coatings, wall coverings or floor coverings. Thus, at the same time, the textile or carpet structures of the present invention may be used in various techniques, or in-line, including lamination of pre-formed pre-cured layers of foam material, lamination of pre-formed first carpet and pre-formed foam layers. It is suitable for manufacturing by the application method. It is contemplated that the resilient adhesive material layer (s) may be substantially discontinuous with one another, or may be mixed across this material layer if a sufficiently porous stabilizing material is present. Thus, the term "layers" refers to both such discrete and mixed masses. Therefore, the structure of the present invention features its substantial variety that can be produced by both simple and more delicate manufacturing methods. In view of the foregoing description, a general purpose of one or more embodiments of the present invention is to provide a cushion or foam backing surface coating, wall covering, having a foam layer or cushion formed of a material made from compressible particles (eg, recombination foam) bonded to each other, One or more textile products, composites or structures, such as floor coverings, flooring materials, carpets or carpet tiles.

A further object of one or more embodiments of the present invention is to provide a cushion or foam backing carpet or carpet tile.

Another object of one or more embodiments of the present invention is to provide a carpet tile having a carpet of surface weight of about 45 oz / yd ² or less.

Another object of one or more embodiments of the present invention is to provide a carpet tile having a resilience or hot melt layer of about 70 oz / yd ² or less.

Another object of one or more embodiments of the present invention is to provide a carpet tile having a light weight surface and / or a cushion.

A further object of one or more embodiments of the present invention is to provide a carpet tile having a light weight cushion of about 0.04 to 0.50 inches thick, preferably 0.04 to 0.09 inches thick.

Another object of one or more embodiments of the present invention is to provide a carpet tile having a recombination foam or compressed particle cushion having a density of about 25 lbs / ft ³ or less.

Another object of one or more embodiments of the present invention is to provide a carpet tile having recombination foam or compressed particle cushion having a density of about 4 to 25 lbs / ft ³ .

It is a further object of one or more embodiments of the present invention to provide a carpet tile having a light weight cushion having a weight of about 26 oz / yd ² or less.

It is a further object of one or more embodiments of the present invention to provide a carpet product or carpet tile having a foam material together with regenerated foam and / or particulate content.

It is a further object of one or more embodiments of the present invention to provide a carpet product or carpet tile having a backing with one or more flame laminated junctions.

It is a further object of one or more embodiments of the present invention to provide a cushion or foam backing carpet or carpet tile having layers of compressible particles bonded to each other.

Another object of one or more embodiments of the present invention is to provide a carpet product or carpet tile having one or more recombination foam layers.

A further object of one or more embodiments of the present invention is to provide carpet products or carpet tiles having a delamination strength greater than 5 lbs per linear inch according to ASTM 3936.

It is a further object of one or more embodiments of the present invention to provide modular carpet tiles having resilience and under foot comfort.

It is another object of one or more embodiments of the present invention to provide modular carpet tiles that exhibit performance characteristics that are evaluated for commercial scale mass use.

A further object of one or more embodiments of the present invention is to provide a method of forming a foam or cushion backing textile product, such as flooring, carpet, carpet composite, carpet tile, and the like.

Another object of one or more embodiments of the present invention is to provide a method of forming modular carpet tiles having resilience and foot comfort, exhibiting performance characteristics evaluated for commercial use on a large scale.

It is an object of one or more embodiments of the present invention to provide a foam backing or cushion carpet composite or tile in which a reinforcing layer is disposed in or below the first carpet.

A related object of one or more embodiments of the present invention is to provide a foam backing or cushion carpet composite or tile wherein the first carpet fabric is bonded to the reinforcing layer and the foam compressive or cushion backing.

It is a further object of one or more embodiments of the present invention to provide a method of forming a foam backing or cushion carpet composite or tile comprising a first carpet fabric, a reinforcing layer, a polyurethane cushion material and a backing layer.

A further related object of one or more embodiments of the present invention is to provide a method of continuously forming a foam backing or cushion carpet composite having a reinforcing layer between the first carpet and the backing layer.

A further object of one or more embodiments of the present invention is to provide a method of forming a foam backing or cushion backing carpet composite or article having a cushioning backing attached by a first carpet fabric and an adhesive layer thereto.

A further related object of one or more embodiments of the present invention is to provide an apparatus for continuously forming a foam backing or cushion backing carpet composite.

Another object of one or more embodiments of the present invention is that the carpet composites and carpet tiles of the present invention may or may not use conventional quarter turn " Parquet " Not only by the ashler (brick) technique, but also by means of a design or orientation-independent design that has the ability to properly seal to fit the design without the tile being cut and the carpet to be integrally installed. have.

According to an exemplary object of the one or more embodiments of the invention, the module carpet tile module carpet composite which can be cut to form, for example, about 45oz / yd ² or less of the surface weight, about 70oz / yd ² hot melt layer of a less And a first carpet or greige carpet having a cushion about 0.04 to 0.50 inches thick. The cushion may have a density of about 25 lbs / ft ³ or less.

Another object of one or more embodiments of the present invention is preferably a compressed content having recycled content and having unexpectedly good appearance, wear resistance, resilience and foot comfort, and having performance characteristics evaluated for commercial scale mass use. It is to provide a modular carpet composite or modular carpet tiles incorporating particle foam or recombination foam. Therefore, by using these carpet composites or carpet tiles in place of standard cushion backed or hard backed carpet tiles or wide carpets, you can reduce costs, reduce material requirements, reduce weight, reduce energy requirements, reduce environmental impact, etc. can do.

According to the particular purpose of one or more embodiments of the invention, for example, a 6 or 12 foot wide modular carpet composite can be for example 18 inches × 18 inches, 36 inches × 36 inches, 50 cm × 50 cm, 1 meter × 1 It is cut into modular carpet tiles or carpet squares such as meters, 48 inches by 48 inches, and the like.

In addition, according to another object of one or more embodiments of the present invention, the carpet composites or carpet tiles of the present invention are positioned by any conventional installation technique, not just that they can be configured for adhesive-free installation, self-adhesive, etc. Or on the floor.

Furthermore, according to another object of one or more embodiments of the present invention, the carpet composites and carpet tiles of the present invention require the tile to be cut to conform to an orientation dependent design, or design and with or without floor adhesive. It can be printed with a design that has the ability to properly seal the carpet so that it is integrally installed.

According to one or more embodiments of the present invention, a carpet composite or carpet tile having good appearance, feel, abrasion resistance, resilience, and underfoot comfort and having performance characteristics evaluated for commercial use on a large scale may be used to heat the first carpet. It may be formed by combining with a molten or resilient layer and a recombination foam cushion.

According to one or more embodiments of the present invention, the low weight modular carpet tiles are provided to have an overall height of about 0.10 to 0.75 inches thick, preferably 0.20 to 0.50 inches thick, depending on the structure (number of layers or components) of the carpet tiles. It can be cut into any conventional shape or size.

The carpet composites of one or more embodiments of the present invention are particularly suitable for modular carpet tiles, but have applications such as other carpets or floorings such as carpets, broad carpets, area rugs, runners, floor mats and the like. .

It is a feature of one or more embodiments of the present invention to provide a cushion carpet composite or carpet tile comprising a first carpet fabric in a laminar relationship with a reinforcing layer at least partially embedded in the recombination foam layer. The reinforcement layer may be bonded to the base of the first carpet fabric and / or polyurethane foam.

It is a feature of one or more embodiments of the present invention to provide a cushion carpet composite or carpet tile comprising a first carpet fabric in a laminar flow relationship with a polyurethane foam disposed adjacent a nonwoven backing layer.

It is a feature of one or more embodiments of the present invention to provide a cushion carpet composite or carpet tile comprising a first carpet fabric in a laminar flow relationship with a reinforcing layer and a recombination foam layer. The reinforcement layer may be bonded to the base of the first carpet fabric and / or polyurethane foam.

Additional features of one or more embodiments of the present invention provide a process for forming a cushion carpet composite comprising a simultaneous continuous step of adhering one or more reinforcing materials to the base of the first carpet fabric and / or to the top surface of the cushion layer. It is.

An additional feature of one or more embodiments of the present invention is a process for forming a cushion carpet composite comprising adhering a reinforcing material to the base of the first carpet fabric and adhering the recombined polyurethane foam and backing layer to the reinforcing material. To provide.

Additional features of one or more embodiments of the present invention include forming or obtaining a first carpet fabric, forming or obtaining a recombined polyurethane foam layer, and adhering the first carpet fabric to the recombined polyurethane foam layer. It is to provide a process for forming a cushion carpet composite comprising the step.

Another additional feature of one or more embodiments of the present invention includes a device for adhering one or more adhesive application units or reinforcing layers to the top surface of the first carpet fabric and / or foam layer, the continuous in-line of the cushion carpet composite. It is to provide an apparatus to be used for formation.

An additional feature of one or more selected embodiments of the present invention is the formation of a cushion carpet composite comprising a polymer application unit for depositing an adhesive composition or other suitable polymer on the base of the first carpet fabric and the top surface of the foam or cushion layer. To provide a device to use.

Another additional feature of one or more embodiments of the present invention is to provide an apparatus for use in forming a cushion carpet composite, comprising an adhesive application device for adhering the reinforcing layer to the base of the first carpet fabric.

In accordance with one or more embodiments of the present invention, foam backing or cushion carpets, composites or tiles are provided. The cushion carpet includes a first carpet having a first base and a plurality of pile-forming yarns projecting outwardly from one side. A layer of reinforcing material is bonded to the first base on the opposite side of the pile-forming yarn. The reinforcing material is attached adjacent to a foam or cushion layer, such as a recombination foam. The optional backing material is preferably disposed on the underside of the cushion layer. The backing layer may comprise an adhesive backing on the opposite side to the cushion layer.

In accordance with one or more embodiments of the present invention, foam backing cushion carpets, composites, or tiles are provided. The cushion carpet includes a first carpet having a first base and a plurality of pile-forming yarns projecting outwardly from one side. The layer of reinforcing material is bonded to the first base on the opposite side of the pile-forming yarn. The reinforcing material is adjacent to the foam or cushion layer of the polymer, such as polyurethane recombination foam. The optional backing material is preferably disposed on the underside of the cushion layer. The backing material may include an adhesive backing opposite the cushion layer.

According to one or more embodiments of the present invention, foam backing or cushion carpets, composites, or tiles are provided. The cushion carpet includes a first carpet having a first base and a plurality of pile-forming yarns projecting outwardly from one side. The cushion layer is bonded to the first base on the opposite side to the pile-forming yarn. The reinforcing material may be embedded in a cushion layer, such as two layers of polyurethane recombination foam. The cushion layer may be bonded to the first carpet by a layer of adhesive, such as a hot melt. The optional backing material is preferably disposed on the underside of the cushion layer. The backing material may comprise an adhesive backing on the opposite side to the cushion layer.

According to one or more embodiments of the present invention, a process for making a cushion carpet is provided. The process includes making or obtaining a first carpet fabric comprising a plurality of pile-forming yarns extending outwardly from one side of the first base. The layer of reinforcing material is adhered to the first carpet fabric in that the pile-forming yarn does not extend therefrom, forming a preliminary composite. The preliminary composite is then adhered to the foam or cushion layer. After this joining operation, the carpet is rolled, split, cut to size or tiled.

In accordance with one or more embodiments of the present invention, a process is provided for making foam backing or cushion carpets. The process includes obtaining a first carpet fabric comprising a plurality of pile-forming yarns extending outwardly from one side of the first base. The first carpet fabric is then attached to the foam or cushion layer. After this joining operation, the composite is preferably heat cured, coded and then the carpet is cut into tiles.

In accordance with one or more embodiments of the present invention, a process is provided for making foam backing or cushion carpets. The process includes obtaining a first carpet fabric comprising a plurality of pile-forming yarns extending outwardly from one side of the first base. The layer of reinforcing material is adhered to the first carpet fabric in that the pile-forming yarn does not extend therefrom, forming a preliminary composite. The preliminary composite is then attached to the recombination foam or cushion layer. After this joining operation, the composite is rolled up, divided or cut into tiles.

According to one or more embodiments of the present invention, an apparatus for use in forming a foam backing or cushion carpet composite is provided. The apparatus includes a reinforcing bonding unit for bonding a layer of reinforcing material to the underside of a first carpet fabric to form a pre-carpet composite, and a bonding unit for bonding the pre-carpet composite to a foam or cushion layer. Units and conjugation units are operable in a continuous, simultaneous manner.

According to one or more embodiments of the present invention, an apparatus for use in forming a foam backing or cushion carpet composite is provided. The apparatus comprises a reinforcing bonding unit for bonding a layer of reinforcing material to the underside of a first carpet fabric to form a pre-carpet composite, a polymer application unit for dispersing a polymer composition across the surface of the cushion layer, and the carpet composite Bonding unit for joining the cushion layer.

According to one or more embodiments of the present invention, an apparatus for use in forming a foam backing or cushion carpet composite is provided. The apparatus includes a reinforcing bonding unit for bonding a layer of reinforcing material to the bottom of the first carpet fabric and the top of the cushion to form a carpet composite.

In accordance with one or more embodiments of the present invention, a modular carpet tile tufts the broad end to a weight of about 45 oz / yd ² or less, prints the design in the form of a wide end, applies a recombination foam or cushion backing system, and carpet tiles It is manufactured by cutting to be.

Potentially preferred modular carpet tiles of one or more embodiments of the invention exhibit aesthetically pleasing and performance characteristics that are evaluated for commercial, hospitality, and / or residential use. The combination of carpet fabric, adhesives, and cushion backing also provides resilience and foot comfort.

Carpets, composites, and tiles of one or more embodiments of the present invention may comprise a. Tufted carpet, b. The applied design, pattern, or color, and c. It is particularly suitable as a widespread stage or roll product because of the attached recombination foam or cushion backing.

In one or more embodiments of the present invention, a reinforcing layer is disposed below the first carpet and in the middle of the separated or intermixed layer of the resilient polymeric adhesive over the foam or cushion layer such that at least a portion of the polymeric adhesive is faced to the reinforcing layer. Composite foam backings or cushion carpets or tiles are provided that are disposed on and extend therefrom.

According to one or more embodiments of the present invention, the polymeric adhesive is disposed on the first carpet by placing a reinforcing layer in the middle of the separated or intermixed layer of the resilient polymeric adhesive below the first carpet and adjacent the top surface of the foam layer. A structure of a foam backing or cushion carpet composite is provided wherein the foam backing is bonded to the foam layer and the reinforcement layer is disposed at an intermediate position between the first carpet and the foam layer.

According to one or more embodiments of the present invention, a reinforcing layer of fiber glass is disposed between the separated or intermixed layers of the resilient polymeric adhesive below the first carpet and above the foam layer to form the polymeric adhesive. A foam backing or cushion carpet composite is provided wherein at least a portion of the reinforcing layer is disposed on at least one side of the reinforcing layer.

According to one or more embodiments of the present invention, a reinforcing or stabilizing layer or material is disposed between the separated or intermixed layers of the resilient polymeric adhesive below the first carpet and above the foam layer to form the polymeric adhesive. A foam backing or cushion carpet composite is provided in which at least a portion of the material is disposed on at least one side of the intermediate layer.

According to one or more embodiments of the present invention, a reinforcing or stabilizing layer is disposed in the middle of a separate or intermixed layer of adhesive below the first carpet and above the foam or cushion layer such that at least a portion of the adhesive is formed of the reinforcing or stabilizing layer. Foam backing or cushion carpet composites are provided that are arranged on at least one side.

According to one or more embodiments of the present invention, a recombination foam backing or at least one reinforcing layer or material is disposed below the first carpet and over the foam or cushion layer such that at least a portion of the adhesive is disposed on at least one side of the reinforcing layer or material or Cushion carpet composites are provided.

According to one or more embodiments of the present invention, a reinforcing layer of glass material is disposed adjacent to one or more layers of adhesive below the first carpet and above the foam layer such that at least a portion of the adhesive is disposed on at least one side of the reinforcing layer. Cushion carpet composites are provided.

According to one or more embodiments of the present invention, a foam backing or cushion carpet composite is provided wherein at least one reinforcing layer is disposed in between the first carpet and the foam or cushion layer.

According to one or more embodiments of the present invention, a foam backing or cushion carpet composite is provided wherein one reinforcing or stabilizing layer is disposed below the first carpet.

According to one or more embodiments of the present invention, a foam backing or cushion carpet composite is provided wherein one reinforcing or stabilizing layer is disposed over the foam or cushioning layer.

According to one or more embodiments of the present invention, a foam backing or cushion carpet composite having one or more reinforcing or stabilizing layers is provided.

According to one or more embodiments of the present invention, the foam backing or cushion carpet composite is provided with a first carpet over the foam or cushion layer.

According to one or more embodiments of the present invention, a foam backing or cushion carpet composite is provided wherein the reinforcing or stabilizing material or layer is disposed within or adjacent to the first carpet or foam or cushion layer.

According to one or more embodiments of the present invention, the foam backing or cushion carpet composite is provided with a layer of one or more thermoplastic or thermoset adhesives.

In accordance with one or more embodiments of the present invention, a method of forming a foam backing or cushion carpet composite is provided.

In accordance with one or more embodiments of the present invention, a lamination process is provided for forming a foam backing or cushion carpet.

In accordance with one or more aspects of the present invention, an in-line process is provided for forming a foam backing or cushion carpet composite.

According to one or more embodiments of the present invention, a reinforcing layer of nonwoven glass is disposed below the first carpet and above the foam layer such that the hot melt polymeric adhesive is between one side of the first carpet and the foam layer. A cushion carpet composite or tile extending in a connection relationship such that the reinforcement layer is retained in the hot melt polymeric adhesive at a location between the foam layer and the first carpet such that at least a portion of the hot melt polymeric adhesive extends from the side of the reinforcement layer. This is provided. An optional backing material or multicomponent backing composite may be disposed on the underside of the cushion layer.

According to one or more specific examples or embodiments of the present invention, preformed recombination foams or pads are used to make commercial grade cushion carpet tiles. Recombination pads of about 13 lb / ft ³ density are modified, for example by flame lamination, to have respective nonwoven materials bonded to their respective top and bottom surfaces. The composite recombination pad has a thickness of about 0.25 ", which is split in half to produce two foam backings each having a thickness of about 0.125" with nonwoven material attached to one surface. Each divided backing is then bonded directly to a pre-coated tuft carpet or latex based binding carpet using a hot melt adhesive and cut into tiles.

In accordance with one or more embodiments of the present invention, the cushion carpet composite or tile is provided with a frictional or adhesively reinforced backing surface, material, or composite, such as a woven or embossed surface, viscous surface, adhesive surface, magnetic sheet, magnetic strip, and the like.

According to one or more embodiments of the present invention, a 6ft wide cushion wide end, a 12ft wide cushion wide end, a 4ft × 8ft cushion sheet or tile, a 4ft × 4ft cushion sheet or tile, a 36 inch × 36 inch tile, 1 meter × Foam or cushion backing carpet or flooring composites such as 1 meter tiles or the like are provided.

The present invention relates to textile products, composites or structures, such as surface coatings, wall coverings or floor coverings, including floorings, carpets, carpet tiles, components thereof, and the like. More specifically, the present invention relates to a structure for a cushion carpet composite or carpet tile incorporating a foam or cushion material, such as a recombination foam or a compressed particle foam. Also provided are processes, methods, and apparatus for making, forming, installing, or using the cushion- or foam-backed composites or structures of the present invention.

Specific exemplary embodiments or examples of the present invention will be presented with reference to the following attached drawings, which are incorporated herein and constitute a part of this specification.

1A is a side cross-sectional view of a tuft carpet of a cushion composite structure.

1B is a side cross-sectional view of a bonding carpet incorporating a cushion composite structure.

2 is a schematic process diagram illustrating an assembly process for forming a carpet structure according to one embodiment of the invention.

3A is a side cross-sectional view of a carpet structure in accordance with one embodiment of the present invention incorporating a roof pile tuft first carpet surface.

3B is a side cross-sectional view of a carpet structure according to another embodiment of the present invention incorporating a cut loop-tuft first carpet surface.

3C is a cross-sectional side view of a carpet structure according to yet another embodiment of the present invention incorporating a bonded first carpet surface.

4 is a schematic process diagram illustrating an assembly process for forming a carpet structure according to another embodiment of the present invention.

5 is a schematic process line for the assembly of a carpet structure according to yet another embodiment of the present invention.

5A is a schematic process line for the assembly of a carpet structure according to yet another embodiment of the present invention.

FIG. 5B shows another process line for the assembly of another carpet structure in a still further embodiment of the present invention in a view similar to FIG. 5.

6A is a side cross-sectional view of another embodiment of a loop pile tuft carpet structure without individual adhesive pre-coats.

6B is a side cross-sectional view of another embodiment of a cut pile tuft carpet structure without a separate adhesive pre-coat.

FIG. 7A is a side cross-sectional view of another embodiment of a loop pile tuft carpet structure having a reinforcing layer disposed between two different adhesive layers. FIG.

7B is a cross-sectional side view of another embodiment of a cut pile tuft carpet structure having a reinforcing layer disposed between two different adhesive layers.

7C is a side cross-sectional view of another embodiment of a bonded carpet structure having a reinforcing layer disposed between two different adhesive layers.

8A is a cross-sectional side view of another embodiment of a loop pile tuft carpet structure having a reinforcing layer disposed between two latex adhesive layers.

8B is a side cross-sectional view of another embodiment of a cut pile carpet carpet structure having a reinforcing layer disposed between two latex adhesive layers.

9A is a side cross-sectional view of another embodiment of a loop pile tuft carpet structure having glass reinforcement material disposed across the bottom of the first backing.

10A is a side cross-sectional view of another embodiment of a loop pile tuft carpet structure comprising a multicomponent backing composite.

10B is a cross-sectional side view of another embodiment of a cut pile tuft carpet structure comprising a multicomponent backing composite.

10C is a cross-sectional side view of another embodiment of a binding carpet structure that includes a multicomponent backing composite.

11A is a side cross-sectional view of another embodiment of a loop pile tuft carpet structure including a foam cushion without backing.

11B is a side cross-sectional view of another embodiment of a cut pile tuft carpet structure including a foam cushion without backing.

11C is a cross-sectional side view of another embodiment of a bonded carpet structure including a foam cushion without backing.

12A is a cross-sectional side view of another embodiment of a loop pile tuft carpet structure that includes a foam cushion with a release adhesive backing.

12B is a side cross-sectional view of another embodiment of a cut pile tuft carpet structure that includes a foam cushion with a release adhesive backing.

12C is a side cross-sectional view of another embodiment of a bonded carpet structure that includes a foam cushion with a release adhesive backing.

13A is a side cross-sectional view of another embodiment of a loop pile tuft carpet structure that includes a multicomponent composite backing that includes a peelable adhesive on the bottom.

FIG. 13B is a side cross-sectional view of another embodiment of a cut pile tuft carpet structure that includes a multicomponent composite backing that includes a peelable adhesive on the bottom. FIG.

FIG. 13C is a cross-sectional side view of another embodiment of a bonded carpet structure that includes a multicomponent composite backing that includes a release adhesive on the bottom.

14A is a side cross-sectional view of another embodiment of a tuft carpet structure of a cushion composite structure.

14B is a side cross-sectional view of another embodiment of a bonded carpet structure incorporating a cushion composite structure.

15A is a cross-sectional side view of yet another embodiment of a tuft carpet structure incorporating a structure formed by the apparatus and method of the present invention.

15B is a cross-sectional side view of yet another embodiment of a bonded carpet structure incorporating a structure formed by the apparatus and method of the present invention.

16A is a side cross-sectional view of another embodiment of a tufted carpet structure without a reinforcing layer.

16B is a side cross-sectional view of another embodiment of a bonded carpet structure having no reinforcing layer.

17A is a side cross-sectional view of another structure for a tuft carpet structure.

17B is a side cross-sectional view of another structure for the bonded carpet structure.

18A and 18B are representative simple schematic flow diagrams and more complex schematic flow diagrams of modular carpet tile manufacturing in accordance with selected embodiments of the present invention.

19-27 are side cross-sectional views of structures or layers of representative tufts and bonding carpets, composites, or tiles, in accordance with various embodiments, embodiments, or aspects of the present invention.

While FIGS. 19A and 20-27 show tuft loop piles in a first carpet and FIG. 19B shows cut pile first carpet, a tuft or combined loop and / or cut pile can be used and the It is understood that the file may be decorated, printed, dyed and / or otherwise processed depending on the purpose.

28-30 relate to one embodiment of a method of making a recombinant foam sheet or pad useful for the carpet structure of the present invention.

28 is a schematic diagram illustrating a method and apparatus for forming recombination precursors or slurries of chips and binders.

29A and 29B are representative schematic diagrams illustrating the preparation of recombination foam blocks or logs from the slurry of FIG. 28.

30 is a schematic diagram illustrating preparation of a recombination foam sheet or layer according to an exemplary embodiment.

31-32 show an exemplary assembly process of the carpet structure from the recombination foam sheet of FIG. 30.

FIG. 31 is a schematic diagram illustrating the manufacture of a flame-laminated cushion or foam composite comprising the foam layer of FIG. 30 in accordance with an exemplary embodiment of the present invention. FIG.

FIG. 32 is a schematic diagram illustrating an example process line for assembly of a carpet structure including the cushion or foam composite of FIG. 31.

FIG. 33 illustrates a micrograph of a cross section of a conventional polyurethane foam cushioning material. FIG.

FIG. 34 illustrates a micrograph of a cross-section of a small chip size polyurethane recombination foam material according to one or more embodiments of the present invention.

FIG. 35 is a graphical representation of a comparison of Hexapod ratings of various products. FIG.

36 and 37 are side cross-sectional views of other embodiments of woven and nonwoven carpet or flooring structures, respectively.

38 is a schematic process diagram illustrating an assembly process for forming a carpet structure according to another embodiment of the present invention.

39 and 40 are side cross-sectional views of tufted and bonded carpet structures, respectively, according to another selected embodiment of the present invention.

41 is a cross-sectional side view of another embodiment of a tuft carpet structure that includes a composite backing that includes a magnetic sheet.

42 and 43 are side cross-sectional and end structure or layer views of tufted carpet composites or tiles each including a backing with embedded magnetic strips.

44 and 45 are side cross-sectional structure or layer diagrams of tufted carpet composites or tiles including backing of coating or film material, respectively.

Although the present invention has been described above and will be described and described below in connection with certain preferred embodiments, examples, practices and procedures, it does not limit the invention to these specific embodiments, examples, practices and procedures. Rather, it is intended to embrace all such alternatives and modifications that fall within the true spirit and scope of the present invention and all equivalents thereof, as defined and defined only by the claims appended hereto.

According to one or more embodiments of the present invention, there is provided a cushion composite or structure suitable for use in protecting surfaces or articles such as surface coverings, wall coverings and floor coverings, or for protecting products including wide carpets or floor coverings or modular carpet tiles. do. The basic assembly process of the components in the carpet structure according to the invention is provided in FIGS. 2, 3A, 3B and 3C. As described in accordance with the preferred preferred embodiment, the tufted or bonded carpet structures 110A, 110B, 110C of the present invention are layered with a pile forming first carpet fabric 112 on top of the sheet of reinforcing material 158. And the sheet of reinforcing material may comprise any of the backing layers 170 (FIGS. 3A, 3B, 3C) or multicomponent backing composites (FIGS. 10A-C and 13A-C), which are further described below. Located on top of a layer of cushioning or foam 178, such as recombination foam or compressed particle foam. Optional backing layer 170 is preferably a nonwoven or woven fabric of polyester, polypropylene, polyester / polypropylene, polyester / polypropylene / acrylic, other suitable fibers or blends, and may contain colorants, binders, and the like. have. Depending on the composite's cotton composition, a nonwoven structure of about 80% polyester fiber and about 20% polypropylene fiber, about 50% polyester fiber and about 50% polypropylene fiber, or about 100% polyester fiber It may be particularly desirable.

In addition, a blend of 50% polyester fiber, 20% polypropylene and 30% acrylic fiber can be used. Polyester, polypropylene and / or acrylic fibers may have one or more selected colors to give the backing the desired color or appearance. In one embodiment, the foam or backing has a similar color. In certain embodiments, the foam and / or backing has a green, blue, purple or gold color. The color of the backing can be achieved for example by using white polyester fibers and colored acrylic fibers or by using colored polyester and / or polypropylene fibers.

The sheet of reinforcing material 158 is preferably positioned between adhesive layers 160, such as a thermoplastic adhesive or a thermosetting adhesive (preferably a hot melt adhesive, etc.) extending to each side of the sheet of reinforcing material 158. Thereby forming a bond between the first carpet fabric 112 and the recombination cushioning or foam 178. As noted above, the adhesive layers 160 may form a barrier between the layers to substantially separate the reinforcing material 158, or the adhesive layers 160 may be at least partially mixed with each other in the reinforcing material 158. have. In each of these cases, the adhesive layer 160, which is in engagement with the reinforcing material 158 due to the close bonding relationship between the reinforcing material 158 and the adhesive layers 160, is the cushioning foam or the recombination foam 178 and the first carpet. A crosslinked composite is formed that extends substantially stably between the fabrics 112.

It is also contemplated that the first carpet fabric 112 may combine tufts or joined arrangements (loop or cut piles) as described with respect to FIGS. 1A and 1B and 3A, 3B and 3C. In addition, the first carpet 112 may take any number of other pile forming or non-pile forming structures, such as but not limited to flat or textured yarn fabric having a woven, knitted or nonwoven structure. May be considered (FIGS. 36-37).

In a preferred preferred embodiment, the first carpet fabric 112 preferably comprises a plurality of pile-forming yarns projecting outwardly from one side of the first base. If the first carpet 112 used in the present invention is a tuft carpet, as described in FIGS. 3A and 3B, its arrangement is substantially consistent with that of the first carpet 12 described in FIG. The difference is that the pile forming yarns 121 in the embodiment shown in FIG. 3B are subjected to tip shear or loop cutting to form a cutting pile structure. If the first carpet 112 used in the present invention is a bonded product as described in FIG. 3C, it will be preferable that the arrangement thereof is an array of bonded first carpet 12 as described in FIG. 1B. It is also contemplated that the first carpet can include one or more backing or base layers.

It should also be understood that the component construction of the first carpet fabric 112 is not critical to the present invention, as the first tuft or bond carpet fabric 12 may have other embodiments. Rather, any first carpet fabric with pile formation and a first base or backing can be used as the first carpet fabric. “First base” may be any single layer or composite structure, such as a product in combination with a first backing 22 and a latex pre-coat 24 previously described with respect to a tuft product (FIG. 1A). A commonly used layered composite with an adhesive layer 36 having a reinforcing substrate 38 already described with respect to FIG. 1B). As expected, the use of polyesters or stabilized materials in the first base structure may be desirable because of the final heat cure performed on the structure. Of course, other embodiments that may occur to those skilled in the art may also be used. For example, in a bonded product, the pile former may be heat fixed to the substrate 38 to form a simple first carpet structure, as described in US Pat. No. 5,443,881, which is incorporated herein by reference.

Still other embodiments may be useful as well, including those described in US Pat. No. 4,576,665 to Machell, which is incorporated herein by reference. For example, a first specialized backing, such as a nonwoven structure comprising glass fibers sandwiched between layers of polyester, is presently present in the manner described later by using it on the first tuft carpet to impart desired properties with respect to stability. The need for a second backing or latex pre-coat being used can be significantly reduced or even eliminated. Moreover, if a pre-coat is used, it can be added directly during the operation immediately before any adhesive bonding is carried out.

In one embodiment, the tufted carpet structure 110A (FIG. 3A) of the present invention is well known and is provided by a pre-coat layer 124 of a bonding material or adhesive, such as latex, hot melt adhesive or urethane based adhesive. The first carpet fabric 112 preferably includes a loop pile layer of the tuft pile-forming yarn 120 in the first backing 122 held in place. The pre-coat layer 124 can be applied to the first backing 122 in the pretreatment step during the formation of the first carpet fabric 112, or during the formation of the cushion carpet structure in a manner described later in connection with FIG. 5A. It may be considered to be added immediately. Pre-carpet fabric 112 may be steamed and / or heated after addition of pre-coat layer 124 to facilitate subsequent printing operations such as direct or indirect jet dyeing or printing or to reduce stress as needed. Can be. In addition, first carpet fabric 112 may be printed or dyed prior to adding a layer of reinforcing material 158 and / or cushioning material or foam 178.

The two basic first backing structures are woven polyester and nonwoven polyester. Each material can have a variety of constituent properties engineered according to a particular end use. According to an effective preferred embodiment, the preferred first backing material 122 has woven polypropylene at 20 picks per inch with needle punched nylon fleece.

As another embodiment, in the cut pile tuft carpet structure 110B (FIG. 3B) of the present invention, the first carpet fabric 112 is well known and may be formed of a bonding material such as latex, hot melt adhesive or urethane based adhesive. The first backing 122 held in place by the pre-coat layer 124 preferably includes a loop pile layer of tuft pile-forming yarn 120. The pile forming yarn 120 is subjected to a shearing or loop cutting operation to form a cutting pile structure as shown. The pre-coat layer 124 is applied to the first backing 122 in the pretreatment step during the formation of the first carpet fabric 112 or during the formation of the cushion carpet structure in a manner described further below with respect to FIG. 5A. Can be added immediately. The first carpet fabric 112 may be steamed and / or heated after addition of the pre-coat layer 124 to facilitate subsequent printing operations such as direct or indirect spray dyeing or printing or to reduce stress as needed. have.

The two basic first backing structures are woven polypropylene and nonwoven polyester. Each material can have a variety of structural properties engineered for a particular end use. In one effective preferred embodiment, the preferred first backing material 122 has woven polypropylene at 20 picks per inch with needle punched nylon fleece.

In the bonded carpet structure 110C (FIG. 3C) of the present invention, the first carpet fabric 112 is laminated to a reinforcement or substrate layer 138 of a woven or nonwoven material, including fiberglass, nylon, polyester or polypropylene. It preferably comprises a plurality of cutting pile yarns 134 inserted into the ized adhesive 136 (eg, latex or hot melt adhesive). It is contemplated that such substrate layer 138 may be pre-coated with a latex or other thermoplastic polymer to melt bond with the cutting pile yarn 134 upon application of heat.

The yarns 120, 121, and 134 may be spun or filament yarns, and polyamides are available from companies such as DuPont, Wilmington, Delaware, or Solutia Fibers, St. Louis, Missouri, USA. It is preferably formed from a polymer (e.g., nylon 6 staples, nylon 6 filaments, nylon 6,6 staples or nylon 6,6 filaments), but other suitable natural or synthetic yarns or blends are well known to those skilled in the art. Can be used. Examples of other materials that may be used include polyester staples or filaments, polyethylene terephthalate (PET), and polybutylene terephthalate (PBT); Polyolefins (eg, polyethylene and polypropylene staples or filaments); Rayon; And polyvinyl polymers (eg, polyacrylonitrile), although not limited thereto. Various denier, ply, twist degrees, air trapping and thermosetting properties can be used to construct the yarn. Effectively preferred materials include nylon 6,6, filaments, 1360 denier, 1 ply, bit twist, non-air capture, and non-thermal curing; Nylon 6,6, staples, 3.15 cotton count, 2-ply, twisted, and thermoset; Blend filaments having denier of a total yarn of nylon 6,6, about 1360; Blend filaments having denier of a total yarn of nylon 6,6, about 2400; And spun fibers and two plies having a cotton number of nylon 6,6, about 1.8 cc.

Although the yarn (or fiber) is preferably white or light in color to facilitate its injection dyeing or printing, it may be of any nature and color such as saga solution dyeing, natural coloring, dry injection printing, screen printing, It should be understood that it can be modified for transfer printing, graphic tufts, weaving, knitting, and the like.

According to one embodiment, the cotton weight of the yarn for the carpet can be less than about 20 ounces per yard square, preferably up to about 15 ounces per yard square, most preferably up to about 12 ounces per square yard have. It is believed that using non-twisted yarns of sufficient denier (in the range of about 1000d to 1400d) in the non-heatset form can easily achieve flush range even at relatively low cotton weights due to the bulking that occurs during subsequent dyeing and steam operations.

According to another embodiment, the cotton weight of the yarn for the carpet is about 20 to 60 ounces per square yard, preferably about 20 to 28 ounces per square yard.

In tufted products, the adhesive pre-coat 124 is preferably styrene butadiene rubber (SBR) or latex, but styrene acrylate, polyvinyl chloride (PVC), ethylene vinyl acetate (EVA), acrylic, and bitumen, Other suitable materials such as polyurethanes, polyesters, polyamides, EVA or their described hot melt adhesives or blends can likewise be used. In addition, as described later, when hot melt adhesives are used, reinforcing materials such as woven or nonwoven fiberglass, nylon or polyester scrims can be attached directly to form composite laminates without the use of additional adhesive layers. have. Moreover, the adhesive pre-coat 124 is completely removed from the tuft product when the loop pile 120 is tufted in a suitably safe relationship with the first backing 122 and as described in FIGS. 6A and 6B. It is also conceivable that the structure can be calculated.

The carpet structure according to the invention comprising tufted or bonded pile forming first carpet fabric 112 is bonded to the lower sheet of reinforcing material 158 by one or more layers of resilient polymeric adhesive material 160. Can be. The polymerizable adhesive material 160 may be a thermoplastic or thermoset composition. Hot melt material may be particularly preferred. Examples of useful hot melts include, but are not limited to, bitumen, polyolefin-based thermoplastics. One effective preferred hot melt material is a polyolefinic thermoplastic material. Useful thermosetting adhesives include polyurethanes. The total mass of the hot melt adhesive used in the two layers in contact with the reinforcing material is preferably from about 20 to about 100 ounces per yard square of carpet, and more preferably from about 35 to about 90 ounces per yard square of the fabric. Do.

The reinforcing material 158 serves to improve dimensional stability for the carpet structure when the carpet structure is subjected to compressive force during use or to temperature changes during use and / or treatment, thereby substantially preventing the various layers from disproportionately changing the dimension. . The reinforcing material is preferably a sheet, mat or tissue that incorporates a number of fiberglass (glass) fibers captured in the nonwoven structure, such as a ² oz / yd ² structure, and may be held together by one or more binders, such as acrylic binders. . Such structures are believed to provide substantially uniform load durability in all directions, which may be an advantage in some cases. Other materials that can be used include glass scrim materials and woven or nonwoven materials (eg polyester or nylon).

As described in FIGS. 2, 3A, 3B and 2C, polymeric adhesive 160 is preferably disposed in a covering relationship on one side of reinforcing material 158. It is contemplated that this built-in relationship can be achieved by any of a number of manual or automatic techniques. One such technique, which is not intended to be limiting, but can be used, for example, is adhesive 160 on one side of the reinforcing material 158 prior to insertion between the recombination cushioning or foam layer 178 and the first carpet fabric 112. ) Is applied directly. Of course this application can be carried out by any suitable method as known to those skilled in the art, including but not limited to spray coating, dip coating, roll coating or manual application. Consider. However, it is contemplated that the adhesive 160 will extend from each side of the reinforcing material 158 in a covering relationship despite the actual application mechanism as may be used. In this regard, the adhesive preferably serves the dual function of anchoring the reinforcing material 158 in place while forming a bond crosslink between the bottom of the first carpet fabric 112 and the top surface of the cushion foam or recombination foam 178. Consider doing it.

Polyurethane recombination foam or compressed particle foam, with or without backing layer 170 (FIGS. 3A and 3B) or multicomponent backing composites (FIGS. 10A-10C), according to a simple processing arrangement as described in FIG. The preformed layer of 178 is for connection with the reinforcing material 158, which is a non-woven sheet of glass fabric coated on the underside, for example, with a bottom coating of the hot melt polymeric adhesive 160 at the first coating station 192. It is transmitted to the first bonding calendar 191 according to the movement path. An additional top coat of hot melt polymeric adhesive 160 is then applied to the entire top surface of the reinforcement 158 at the second coating station 193. Due to the high surface area and relative porosity of the nonwoven reinforcing material, the polymeric adhesive 160 can at least partially extend through the reinforcing material while at the same time achieving a stable mechanical bond therebetween. The preformed pile forming first carpet fabric 112 as described above is then applied in an overlay relationship to the reinforcing material 158 coated at the second bonding calendar 194 such that the polymeric adhesive 160 is cushioned foam. Or bonds extending between the recombination foam 178 and the underside of the first carpet fabric 112. The resulting structure can be heated or cured at 198 and is substantially as described in FIGS. 3A, 3B or 3C (or FIGS. 6A-9B, 11A-12C, 14A, 14B or 37). By adding another coating station and a bonding calendar, another adhesive layer 1071, 1371 (hot melt tie-coat) may be used to attach the backing material or composite to the bottom of the foam 178 (FIGS. 10A-10C, 13A). To 13C, 23, 41, 42 or 43).

As described in US Pat. Nos. 5,312,888, 5,817,703, 5,880,165, and 6,136,870, which are incorporated herein by reference, recombination foams or recombination polyurethane foams are known in the art as isocyanate based polymeric foams. It is. Specifically, it is known to mix a binder and a foam which serve to bind the pieces together. In particular, recombination techniques have long been used to recycle polyurethane foam. In general, large chip sizes, low densities, non-uniform densities, rather weakly recombined polyurethane foam products have been used as broad carpet carpet underlays or pads, and in certain seating and cushioning applications. It is not surprising that these foams have not been used in cushion backing carpet tile applications because they have non-uniform and weak properties as well as prior uses for such recombination foams.

Polymeric foams, especially flexible polymeric foams, can be processed into sheets, pads, blocks or articles having a useful form. For example, the flexible foam can be molded or machined into a form useful for making car seats, bedding, and the like. Flexible foams can be used in the manufacture of carpets and furniture, as well as in the manufacture of toys and the like.

However, waste foams may be produced in the process of making foam sheets, pads, blocks or standard polymeric foams. Waste foam refers to the area / volume of the foam generated from the processing and from which the crust is removed from the starting stock (or rope), such as forming a standard foam object. Waste foam may also be a crust, trimming, scraping, non-standard product often produced in some processing processes.

Whatever the source, waste foam is usually undesirable. Waste foam may be a material that must be disposed of and not solid. In some areas landfill space has become scarce and waste foam disposal costs have become very high.

Efforts have been made to recycle or reuse waste foam products obtained from the production of flexible foams, specifically waste, trims and scrap. The flexible polyurethane foam scrap is cut and chopped and then coated with a binder consisting of a polyisocyanate prepolymer and catalyst having an isocyanate function. The coated and cut foam is compressed and then steamed to cure the binder to form a recombined foam sheet or other form.

In another process of recycling or using flexible polyurethane foam waste, the flexible foam waste is cryogenically ground and blended back into the formulation used to prepare it. The ground flexible foam can be used in an amount of about 20% in the polyol component of the polyurethane foam formulation.

According to the present invention, about 10 to 100 to produce a cushion carpet composite or carpet tile having a recycled foam or cushion content (especially post-industrial recycled foam or cushion content) in the foam or cushion layer thereof. Using at least about 10-90% recycled foam or bond-bonding foam containing at least% recycled foam, chips, chips, pieces, ground, particles and the like and binders, adhesives or prepolymers (and one or more additives) It is preferable.

In accordance with an embodiment of the present invention with respect to FIGS. 28-30, foam chips, clumps, particles fed into one or more storage hoppers (foam chips of different densities, colors, and types can be stored in each hopper) It is preferable to use a relatively high density, high density, recombination foam material of small chip size formed by shredding or crushing foam material such as foam scrap or waste in a foam shredder to form. Chips blended and mixed from one or more reactors or tanks by feeding foam chips from a hopper into a blend tank where different colors, densities, and types of chips are blended and mixed with one or more binders, adhesives, prepolymers and / or additives. And a binder slurry (eg about 85% chip, 15% binder). The slurry is fed into a large compression cylinder or vessel and compressed (eg 2: 1 to 4: 1) and treated with heat and steam to set or cure the recombination foam in a compressed state (compressed particle foam). After cooling, the recombination foam logs or blocks are removed from the cylinder, and the recombination foam sheets or pads are mounted in a stripping or slicing device having a band knife or other blade from the outside of the logs or rolls or in an apparatus for cutting, slitting or filling. .

With reference to FIGS. 31 and 32, the recombined foam sheet is laminated to the top and / or bottom surface or to the carpet composite or product to form a foam or cushion composite, at least to form or adhere to the carpet or tile material. It may have one or more materials.

According to the invention, it is preferable to use recombination foams having at least one backing, such as scrim, woven or nonwoven fabrics.

According to the invention, about 1 to 25 lb / ft ³ , more preferably about 3 to 22 lb / ft ³ , even more preferably 10 to 13 lb / ft ³ , most preferably 8 to 12 lb / ft ³ Density of; A thickness of about 2 to 20 mm, more preferably about 2 to 21 mm, most preferably about 2 to 7 mm; Recombination chip size (uncompressed chip size) of round or square hole mesh of about 2 to 25 mm, more preferably about 5 to 15 mm, most preferably about 7 to 10 mm; And recombination foam or polyurethane recombination foam having a backing material or backing composite on at least one side.

For example, as described in FIG. 4, a heating element 195, such as flame 196, may be used to heat the top and bottom surfaces of the composite 159 and three preformed materials 112, 159, 178. ) Can be laminated to the preformed recombination foam layer 178 and the first carpet fabric 112 including a hot melt coating pre-coated on one or both sides. Consider that possible. If desired, heat may be applied to the structure or composite produced at 197 to form a product, as shown, for example, in FIGS. 3A-3C, 6A-14B and 23.

As mentioned above, it is contemplated that the hot melt adhesive 160 may be forced through the material due to the relatively porous nature of the reinforcing material 158. Accordingly, it is contemplated that the first coating station 192 of FIG. 2 may be replaced with a forced sprayer, roll, or the like if desired to deposit the hot melt adhesive 160 across both sides of the reinforcing material 158 prior to lamination.

The carpet structure according to the invention can be formed using a simple assembly or lamination process as described and described above with respect to FIGS. Consider that efficiency can be achieved. According to one example of the inline process in connection with FIGS. 5, 17A and 17B, the first carpet fabric 112, with or without the precoating sublayer, is transferred through the accumulator 15 to the reinforcement coupling device 155 by a plurality of rolls. do. At the same time the first carpet fabric 112 is delivered to the reinforcing bond device 155, the sheet of reinforcing material 158 is also transferred to the reinforcement bond device 155. The reinforcing material 158 is preferably a fiberglass nonwoven material, such as 2.0 oz / yd ² fiberglass, containing a urea formaldehyde binder, an acrylic binder, and the like, but another material is merely exemplified by woven glass, woven polyester, Nonwoven glass and nonwoven polyester.

Adhesive 160, such as a hot melt polymeric adhesive, in reinforcing bonding device 155 is preferably applied to at least the top of reinforcing material 158 by a film coater or other means as is well known. The coated reinforcement material 158 and the first carpet fabric 112 are then passed in a bonding relationship, preferably between connecting members, such as rolls 163 and 165, so that the coated reinforcement material 158 is passed through the first carpet fabric. To the bottom of (112). That is, the reinforcing material 158 is bonded to one side of the first carpet fabric 112 where the pile forming sand is not fired. The combination of the reinforcing material 158 and the underside of the first carpet fabric creates a stabilized preliminary composite 166 and another coating of adhesive 160 is applied to the underside of the stabilized precomposite 166 at the coating station 179. Adhesive, hot melt or polyurethane directly on top of the recombination foam layer 178 of the pre-formed recombination foam layer 178 which is applied and substantially surrounds the reinforcing material 158 in the adhesive. Form a stabilized intermediate composite 167 that is laminated to the forming composition layer 180.

While the reinforcing bonding device 155 has been described with the introduction of a film coater, and the coating station 179 has been described with the introduction of a vertical application roll, numerous optional means, such as a spray coater, a blade coater, a dip coater, can also be used. It is to be understood that some optional means for applying the adhesive 160, for example, but not by way of limitation, is disclosed in US Pat. No. 4,576,665 to Marcel.

According to a possible preferred embodiment, the preformed recombination foam layer, composite or sheet 178 forming the precomposite 166 preferably comprises a polymer applicator comprising a polymer discharge device 176 and a doctor blade 177 ( 175). Foam layer 178 is coated with an adhesive or polymer 180, such as a polyurethane-forming composition, described in detail below.

In a preferred embodiment, the preformed foam layer 178 is a backing material 170, for example woven or nonwoven, from about 10% to 100% polyester / 90% to 0% polypropylene, preferably About 50% polyester / 50% polypropylene nonwoven fibrous material or felt (available from Synthetic Industries, Lyngold, GA, and may contain binders such as colorants or acrylic binders) It may include. While this represents a preferred backing material, it should be understood that any of a number of optional compositions or composites may be used provided that they are defined by the requirements for shrinkage and equipment. Commonly used second backing materials include nonwoven polyesters, blends of nonwoven polyesters and polypropylenes, or woven polypropylenes. The backing material may be up to 100% polyester, for example, if only very small shrinkage is allowed or no shrinkage is allowed, for example and not by way of limitation. In addition, although nonwoven backing materials are preferred, it is contemplated that woven or nonwoven structures may be used because materials other than polyester / polypropylene such as acrylic, nylon, fiberglass, etc. may be mixed.

As mentioned, in a preferred implementation, the polymer application device 175 adjusts the height of the polymer layer to the desired level and then the polymer (top) on top of the cushion or foam layer 178 (FIGS. 5, 5A, 17A, 17B). 180) is deposited. In a preferred embodiment, the applied polymer is a polyurethane-forming composition based on so-called soft fragment prepolymers of MDI (diphenylmethane diisocyanate) or MDI derivatives. The polyurethane-forming composition also preferably incorporates a silicone surfactant to improve both the foaming force and stability of the polyurethane layer or “puddle” 180 that develops over the surface of the preformed foam layer 178.

The foam density of the preformed foam layer 178 is preferably in the range of about 1 to 25 lb / ft ³ , preferably about 6 to about 20 lb / ft ³ , and about 0.04 to about 0.5 inches, preferably It has a thickness of about 0.04 to about 0.12 inches. According to one possible preferred arrangement, the foam density is less than about 16 lb / ft ³ and has a thickness of about 0.06 inches, although it is contemplated that this level can be highly dependent on the desired product properties.

It is contemplated that material formation of layer 180 and preformed foam or recombination cushion 178 can be implemented in a wide range of choices. Without wishing to be limiting, but merely for example, four or more options or examples regarding layer 180 and / or foam cushioning material 178 may be employed using pure polyurethane and / or recycled polyurethane chips, chips, granules, and the like. It is believed to be practical for obtaining commercially available foam products.

1. Use a standard filled polyurethane system as pure and / or recombination polyurethane. One polyurethane foam contains 110 parts of filler and is applied at a density of about 15 lb / ft ³ . If the thickness ranges from 0.04 to 0.12 and only the polymer weight can be determined using the density and the filler amount, the weight range of the polymer will be 4.32 to 12.96 oz / yd ² .

2. A second option that may also affect pure and / or recombined polyurethane is to increase the amount of filler to 190 parts and to reduce the density to 13 lb / ft ³ . At the same thickness limit the polymer weight will be from 2.72 to 8.24 oz / yd ² .

3. The third option for pure and / or recombined polyurethane is to use an unfilled polyurethane (prime urethane) system. Such high densities are not possible in prime but they are done because of the fact that there is no wall structure and no fillers at all. Considering that the prime was applied at 6 lb / ft ³ at the above limit thickness, the polymer weight would be 2.88 to 8.64 oz / yd ² .

4. A fourth option is also possible for pure and / or recombined polyurethanes. Textile rubber is a polyurethane system sold under the trade name KANGAHIDE, which has only 15 parts of filler material and is applied at a density of 6 to 9 lb / ft ³ , and recalculates the polymer at the stated thickness limits. Will be 4.3 to 13.02oz / yd ² .

The above embodiment should be carried out using polyurethanes, but water based foam systems may also be used. Polyurethane recombination foams or compressed particle foams (formed from compressible particles, chips, clumps, etc.) are preferred, but other foams (open cells, closed cells) or materials such as SBR foam, PVC foam, polyethylene foam, cork, It is understood that other compressible particles made from rubber and / or the like may also be used.

Potentially preferred polyurethane-forming compositions for use as polymer 180 and virgin and / or recombination polyurethane chips in the recombination foam 178 of the present invention are disclosed in US Pat. No. 5,104,693 to Jenkines. The teachings of which are incorporated herein by reference. Specifically, preferred polyurethane-forming compositions used as virgin and / or recombining polyurethane in recombination foam and / or applied across the surface of foam layer 178 include the following components:

A. at least one isocyanate reactive material having an average equivalent of about 1000 to about 5000;

B. an effective amount of blowing agent; And

C. Polyisocyanate in an amount providing an isocyanate index of about 90 to about 130, wherein at least 30% by weight of the polyisocyanate is from about 500 to about and stoichiometric excess of diphenylmethane diisocyanate (MDI) or a derivative thereof Soft segment prepolymer, which is a reaction product of an isocyanate reactive organic polymer having an equivalent of 5000, the prepolymer having an NCO content of about 10 to about 30% by weight).

Polyurethane-forming compositions also include silicones in the form of organo-silicone polymers, as generally disclosed in U.S. Patent No. 4,022,941 to Prokai et al., The teachings of which are incorporated herein by reference. It is preferred to contain surfactants to improve foaming and stability. Specifically, preferred surfactants are preferably linear siloxane-polyoxyalkylene (AB) block copolymers, in particular polyalkylene oxide methylsiloxane copolymers. One particularly useful silicone surfactant is the trade name L-5614 from Ossi Specialties, Inc. (OSI Specialties, Inc., believed to be 30092 Norcross, Suit 311, Connors Parkway 6525, GA). Available for purchase.

Foaming occurs without curing the layer of polyurethane-forming composition disposed across the surface of the foam layer 178 until the precomposite 166 is laminated to the uncured polyurethane-forming composition puddle 180. A sufficient amount of silicone surfactant is used to stabilize the bubbles in the reaction mixture. Generally, the silicone surfactant is preferably from about 0.01 to about 2 parts by weight per 100 parts by weight of component (A), more preferably from about 0.35 to about 1.0 part by weight, most preferably from component (A) A) is used in an amount in the range of about 0.4 to 0.75 parts by weight per 100 parts by weight.

As discussed above, after placing the polyurethane-forming polymer 180 across the foam layer 178, the layer or “puddle” of the deposited polymer is held at a predetermined height by a doctor blade located in the polymer application unit 175. It is preferred to be doctored with. Simple mechanical doctor blades are preferred, but other equivalent means such as air knives, spray coating, roller coating and the like can also be used. Such air knives are disclosed, for example, in US Pat. No. 4,512,831 (incorporated by reference) to Tillotson.

In one embodiment of the present invention, the intermediate composite 167 of the first carpet fabric 112, which is preferably combined with the coated reinforcing material 158, is formed from the intermediate composite 167 or polyurethane-forming composition ( 180) may be deposited directly on the polyurethane-forming composition 180 immediately after doctoring to a suitable level without the need for significant heating. Thus, the intermediate composite 167, and the foam layer 178 to which the polyurethane-forming composition 180 is applied, can be simultaneously delivered to the mating roll 181 at room temperature immediately after application and doctoring of the polyurethane-forming composition. . As can be seen, the use of recombination foam 178 reduces cost and produces a composite with a high recycle foam content. In a preferred method, at least one side of the intermediate composite 167 may be preheated slightly to improve operational control during lamination and curing, but such preheating is not essential to the formation of the desired product.

In an embodiment of the illustrated in-line or in-situ carpet structure, the adhesive material 160 is deposited adjacent to the cushioning foam 178 layer by this method and extends far from below to the first carpet fabric 112. The layer of reinforcement material is embedded in adhesive material 160 in an intimate position between the cushioning foam and the first carpet fabric 112. Thus, at least a portion of the adhesive material 160 extends away from both sides of the reinforcing layer 158.

Once the intermediate composite 167 has been laminated to the polyurethane-forming composition 180, the resulting composite 168 is heated in the heating unit 182 by conducting, radiating or convection heaters as is well known in the art. It may be heated or cured. Contact conducting heaters may be preferred. Such heating may be performed at a temperature of about 250 to about 325 ° F. for about 2 to about 8 minutes.

After the heat cure operation, the resulting cushion carpet composite 168 formed is smoothed by passing it over a non-directional heat source 185 such as a plate heater or roll heater at about 400 ° F. to fuse any protruding fibers onto the backing material 170. Can be made into one surface Thereafter, the formed carpet composites 110A, 110B, 110C (see FIGS. 3A-3C) will be subjected to cooling, rolling, cutting, slicing, and the like. When producing carpet tiles, it is desirable to cut the carpet composite into carpet tiles almost immediately (rather than rolling) to avoid any unwanted cupping or curling. After cutting the carpet tiles from the composite 168, the carpet tiles are printed or dyed, washed, fixed, dried, cooled, loaded, packaged and stored and / or transported to the consumer.

It will be appreciated that many alternative implementations may be included in the present invention to obtain a finished structure in which the reinforcing layer 158 is enclosed in the adhesive material 160. According to another embodiment of the present invention, the first carpet 112 is washed, steamed, dried, and monolithic, for example, after tufting the unheated yarn through the first backing. Or a loop pile tuft carpet formed by spraying or jet dyeing an orientation independent design, color or pattern, for example, to form a 12 foot wide first carpet precursor of the loop pile 120 and the first backing 122. By using non-heat-fixed yarns and the original tufts of the yarns to a rather long loop length, the yarns are shrunk by washing, steaming, drying and dyeing steps to form smaller, tighter loops and a dense surface of the first carpet To the precursor. The first carpet precursor is then split in half and rolled to form two separate six foot wide rolls 115 of split first carpet precursor 113 (FIG. 5A).

Next, one roll 115 of the split first carpet precursor 113 is used as the initial carpet supplied to the apparatus of FIG. 5A. Latex pre-coat or hot melt adhesive coating 124 is applied to the back side of the first carpet precursor 113 to drive the top of the apparatus of FIG. 5A downstream of the accumulator 150 and upstream of the stiffener coupling unit 155. To form the first carpet fabric 112. For example, a thin layer of latex pre-coat 119 is applied to the back side of first carpet precursor 113 using coating roller 117. The remainder of the process proceeds as described with respect to FIG. 5 above.

According to another possible implementation, and as shown in FIG. 5B, the cushioning foam or the recombination foam 178, in the preformed state, may be formed as described above with respect to FIGS. 5 and 5A. It is contemplated that it may be delivered to mating roll 181 to engage. As can be seen, this preformed cushioning foam 178 is formed using the desired backing material 170 or multicomponent backing composite (FIGS. 10A-10C and 13A-13C) disposed across its underside. May be In addition, the top surface of the preformed foam layer 178 is heated by, for example, a heater 195 and flame 196 to heat or melt the top surface to prevent adhesion of the composite 167 to the foam layer 178. You can also improve.

In addition, the roll applicator 179 of FIG. 5B may be removed and the foam layer 178 may be adhered to the reinforcing material 158 of the composite 166 using a heater 195 and a flame 196. .

Similarly, the polymer application unit 175 or roll applicator 179 of FIGS. 5 and 5A may be removed, and the composite 166 or 167 may be foamed layer 178 by adhesive 160 or polymer 180. It can also be coupled to.

In addition, the reinforcing material 158 or composite 159 and the cladding units associated therewith may be used where additional reinforcing layers or materials are not needed or required, or where the reinforcing materials are already attached to or part of a carpet and / or foam or cushion. If so, it may be removed from the process of FIGS. 2, 4, 5, 5A and / or 5B (FIGS. 15A, 15B, 16A, 19A, 19B, 20, 21, 22, 24, 25 and 36).

The apparatus of the invention tufts the yarn in the first backing, dyes the tuft yarn, pre-coats the backside of the first backing, hot melt coats the fiberglass reinforcing material, and cushions or foam the felt. 2 Molding with or without backing, laminating the first carpet, reinforcing fiberglass, and foam or cushioning layers, heating or curing the laminate, and carpeting the resulting carpet composites with carpet tiles, runners, area coverings It is contemplated that it may include the entire assembly process of cutting with a back, dyeing or printing the cut tiles, and packaging the resulting product. It is also contemplated that, in accordance with the present invention, the process may be divided into its respective steps and carried out in a batch rather than a continuous manner. For example, the first carpet can be molded in one operation and wound on a roll or folded into bins. The cushion, backing or foam layer can be molded in a separate operation to be rolled onto a roll or folded into a bin. The preformed first carpet and cushion backing may be joined by mating units using adhesives, hot melts, hot melts including reinforcing layers, and the like. In addition, the hot melt and reinforcing material composites can be preformed and rolled into rolls or folded into bins. Further, preliminary composite 166, intermediate composite 167, or final composite 168 (FIGS. 5, 5A, 5B) may be preformed and rolled onto a roll or folded into a bin.

As can be seen, there are a number of alternative embodiments and forms for foam backing or cushion carpeting or carpet tiles that may incorporate the features of the present invention. As illustrated in Figures 6A and 6B, wherein components similar to those described above are indicated by corresponding reference numerals within 600 units, the tuft loop pile and tuft cut pile structures 610A and 610B may be removed. It is contemplated to include a first layer of hot melt adhesive 660 extending away from the first backing 622 and extending in contact with a sheet of reinforcing material 658, such as the nonwoven glass or scrim material described above. Thus, the first layer of hot melt adhesive 660 functions to secure the tufts 620 and 621 in place relative to the first backing 622, thereby requiring the use of a separate latex or hot melt pre-coat. Do not have. The second layer of hot melt adhesive 660 extends away from the reinforcing material 658 in contact with the foam cushion or recombination material 678, such that between the first carpet 612 and the foam cushion or recombination material 678. Form a bonding relationship. Thus, a single adhesive layer extends between the top surface of the reinforcing material 658 and the bottom side of the first backing 622. By way of example only and not by way of limitation, the structure may be realized as shown in FIGS. 2, 4, 5 or 5B, or the latex pre-coat 119 may be removed in FIG. It is contemplated that this may be achieved.

Tuft loop pile structure 710A, tuft cut pile structure 710B, as illustrated in FIGS. 7A, 7B and 7C, wherein the same components as those described above are indicated by corresponding reference numerals within 700 units. ) And the combined cutting pile structure 710C is a first layer of elastic adhesive 760 extending away from the top surface of the reinforcing material 758 layer, which extends away from the bottom surface of the reinforcing material 760 '. It may be considered to include a) may be of a different characteristic than the second layer of). In all other respects the configuration is substantially as illustrated and described with respect to FIGS. 3A, 3B and 3C or 6A and 6B, and the assembly is performed by any of the techniques illustrated and described above with respect to FIGS. 2, 4 and 5A-5C. do. By way of example only and not limitation, where the reinforcing material 758 is disposed between two different adhesives, the adhesive 760 extending away from the top surface of the reinforcing material 758 may be, for example, a hot melt. It is contemplated that adhesive 760 ′ extending away from the bottom surface of reinforcing material 758 may be, for example, a polyurethane-forming composition. Further, the adhesive 760 of FIGS. 7A and 7B may be multiple layers of the same adhesive.

8A and 8B, wherein the same components as those described above are indicated by corresponding reference numerals within 800 units, illustrating further possible embodiments of the present invention. In this embodiment, the tuft loop pile structure 810A and the tuft cutting pile structure 810B are reinforced with a first layer of latex adhesive 824 and the reinforcing material 858 extending away from the top side of the reinforcing material 858. A layer of reinforcing material 858 disposed between the second layer of latex adhesive 824 extending away from the bottom side of the. Thus, the latex extends substantially between the top surface of the cushion or foam 878 and the first backing 822, and a layer of reinforcing material 858 is disposed at an intermediate position within this latex. The latex is preferably carboxylated styrene butadiene rubber (SBR) latex. Of course, it is contemplated that other adhesives such as polyvinyl chloride (PVC), ethylene vinyl acetate (EVA) and acrylic resins, as well as similar structures using hot melts or polyurethanes as described above, may be useful.

As mentioned above, incorporation of a stabilizing element into the inner surface of the first backing of the tufted first carpet allows additional stability to be imparted to the structure of the present invention. Exemplary embodiments incorporating such structures are illustrated in FIGS. 9A and 9B, wherein components similar to those described above are indicated by corresponding reference numerals within the 900s. As illustrated herein, tuft loop pile structure 910A and tuft cutting pile structure 910B are via a first backing 922 that incorporates a nonwoven or scrim first backing stabilization layer 923 therein. Tuft pile forming yarns 920 and 921 are included. The first backing stabilization layer 923 may be adjacent to the first backing 922 by sewing or calendering. In addition, point bonding between the structures can be accomplished by incorporating heat activated adhesive fibers into the nonwoven structure. When using a structure incorporating the first backing stabilization layer, due to the stability provided in the reinforced first backings 922, 923, the pre-coat 924 and / or the reinforcing material 958 may be substantially reduced if necessary. Can be removed or removed.

Several possible preferred embodiments 1010A, 1010B, 1010C are illustrated in FIGS. 10A-10C, wherein like components as described above are indicated by corresponding reference numerals within the 1000s. As can be seen, this embodiment corresponds substantially to that illustrated and described with respect to FIGS. 3A-3C except that the backing material 1070 is not in direct contact with the foam cushion or recombination foam 1078. . In contrast, the backing is bonded or laminated to the foam by an adhesive, or the multicomponent composite backing is applied across the underside of the foam cushion 1078. According to the relatively simple embodiment illustrated, such composite backings 1070, 1071 are hot melt or extending in a bonding relationship between the underside of the foam cushion 1078 and the backing material 1070 of a woven or nonwoven structure as described above. And other relatively thin layers of resilient adhesive 1071. These hot melt or other adhesive agent Gillian LES thickness, preferably between about 40oz / yd ² or less, and most preferably from about 20oz / yd ² below. As can be seen, the multicomponent composite can include substantially any number of layers of various materials, including peelable layers, additional adhesive layers, and / or stabilizing layers in various arrangements as deemed useful, These are examples only and are not limited to them. In addition, while multicomponent composite backings have been illustrated with respect to carpet structures substantially corresponding to the structures illustrated and described in FIGS. 3A-3C, such composite backings are described, for example, in FIGS. 6A and 6B, 7A-7C, 8A and 8B described above. Or in many other structures, including the structures of FIGS. 9A and 9B, but are not limited to these examples.

Another set of structures is illustrated in FIGS. 11A-11C, wherein components similar to those described above are indicated by corresponding reference numerals within the 1100s. As shown, these embodiments 1110A, 1110B, 1110C are substantially the same as those illustrated and described in FIGS. 3A-3C except that there is substantially no auxiliary backing in the foam cushion or recombination foam 1178. Corresponds to As can be seen, while the absence of an auxiliary backing has been described with respect to the structure substantially corresponding to the carpet structure illustrated and illustrated in FIGS. 3A-3C, such implementations are described, for example, in FIGS. 6A and 6B, 7A-7C, and FIG. The same can be used for many other structures including 8A and 8B, FIGS. 9A and 9B, or the structures of FIGS. 10A to 10C, but are not limited to these examples.

Several further embodiments are illustrated in FIGS. 12A-12C, wherein like components as described above are indicated by corresponding reference numerals in the 1200s. As can be seen, these embodiments 1210A, 1210B, 1210C provide a thin layer of adhesive peelable adhesive 1287 and access layer 1289 with a backing material 1270 disposed across the bottom. Except that includes, substantially corresponds to those illustrated and described with respect to Figures 3A-3C. A thin access layer 1289 of paper, or other suitable film or material, is disposed such that the installer can peel off under the peelable adhesive to expose the peelable adhesive during installation. As can be seen, such peelable or peel-adhesive adhesives provide a relatively weak bond for tension, but a stronger bond for stress so that carpet elements such as carpet tiles can be peeled off from the underlying surface, but this is not desirable. It is substantially resistant to non sliding motion. The thickness of the releasable adhesive, preferably from about 20oz / yd ² or less, and most preferably from about 5oz / yd ² below.

As can be seen, peelable adhesive backings are illustrated in relation to the structures substantially corresponding to the carpet structures illustrated and described in FIGS. 3A-3C, but such adhesive backings are described, for example, in FIGS. 6A and 6B, 7A-7C described above. 8A and 8B, and many other structures, including, but not limited to, the structures of FIGS. 9A and 9B, and the structures with exposed foam undersides of FIGS. 11A-11C.

As shown in Figs. 13A-13C, components similar to those described above are indicated by corresponding reference numerals within the 1300 band and include an adhesive backing 1387 in which the carpet structures 1310A, 1310B, and 1310C are peelable. In addition, the access layer 1389 is designed to be introduced as a lower surface element of the multicomponent composite backings 1370 and 1371 as described above with respect to FIGS. 10A-10C.

Another example of a tufted carpet product 1400 is illustrated in FIG. 14A, and another example of a bonded carpeted product 1410 is illustrated in FIG. 14B.

In the tuft carpet of FIG. 14A, a first carpet fabric 1412 is embedded in the adhesive layer 1416, where a layer 1418 of glass scrim is embedded. Similarly, recombination foam base composite 1418 is adhered to adhesive layer 1416. In the tuft carpet illustrated in FIG. 14A, the first carpet fabric 1412 is tufted through the first backing 1422 by conventional tufting and a pre-coat backing layer 1424 of latex or other hot melt adhesive. A loop pile layer 1420 held in place by a suitable adhesive, including the like. Recombinant foam base composite 1418 of tuft carpet product 1400 includes a backing layer 1426 bonded or laminated to urethane recombination foam layer 1428 as illustrated.

The bonded carpet product 1410 of FIG. 14B utilizes the same type of recombinant foam base composite 1419 adhesively bonded by an adhesive laminate layer 1416. However, the first bonded carpet fabric 1412 differs from the structure of the tuft product in that it has a cutting pile yarn 1434 implanted in a PVC, latex or hot melt adhesive 1434 having a glass scrim reinforcement layer 1438. Have slightly different components.

The backing layer or backing material 1426 is preferably laminated to the foam 1428 by flame lamination (see FIG. 31). Alternatively, it may be attached by one or more adhesives (see FIGS. 10A-10C).

Another example of a tufted carpet product 1500 is illustrated in FIG. 15A, and another example of a bonded carpet product 1510 is illustrated in FIG. 15B.

In the tuft carpet of FIG. 15A, a first carpet fabric 1512 is attached to the adhesive layer 1560. Likewise, the recombinant foam base composite is bonded to the adhesive layer 1560. In the tuft carpet illustrated in FIG. 15A, the first carpet fabric 1512 is tufted through the first backing 1522 by conventional tufting and pre-coat backing layer 1524 or other hot melt of latex A loop pile layer 1520 that is held in place by a suitable adhesive, including an adhesive or the like. The recombination foam based composite of the tufted carpet product 1500 is formed on each side of the layer 1578 of the urethane recombination foam, bonded or laminated (see FIGS. 31 and 32) and the backing layer 1558 and the backing layer ( 1570).

In at least one bonded carpet structure of the present invention (see FIG. 15B), preferably the first carpet fabric 1512 is implanted in a latex or hot melt adhesive 1536 laminated to a glass scrim reinforcement layer or substrate layer 1538. A plurality of cut pile yarns 1534 is included. This substrate layer 1538 may be pre-coated with a latex or other thermoplastic polymer that is melt bonded with the cutting pile yarn 1534 upon application of heat, potentially reducing or eliminating the need for latex or hot melt adhesive 1536. It is designed to be.

Preferably, adhesive 1560 (see FIGS. 15A and 15B), such as a hot melt adhesive, is applied to carpet 1512 or reinforcing material 1558 with well known film coaters or other devices.

In the embodiment illustrated in FIGS. 15A and 15B, layer 1558 of reinforcing material is adjacent to, preferably at least partially embedded in, layer 1578 of recombination polyurethane. That is, the reinforcing material 1558 is in intimate contact with the polyurethane 1578 so that the polymeric material holds the reinforcing material in place (see FIG. 31).

It is appreciated that a number of alternative implementations can be incorporated into the present invention to produce slightly different products. By way of example only, removing the reinforcing material from the process can make the at least one adhesive application device or adhesive layer completely unnecessary. In this case, the first carpet fabric is positioned adjacent to the recombination cushion or cushion composite such that the polyurethane recombination foam 1678 or upper layer (fiber glass) is directly adjacent to the first carpet fabric 1612, FIGS. 16A, 16B, Composite structures as illustrated in 26 and 27 can be created. It is preferable that the recombination foam is laminated to the carpet by the flame lamination method (see FIG. 31).

According to another embodiment, a hot melt or adhesive layer can be used to bond the first carpet to the cushion layer with or without reinforcement material (FIGS. 19A, 19B, 22, 23, 24, 25, 42). , 43, 44 and 45).

In another embodiment, the cushion backing may have an adhesive quick release backing that is attached to the side where the polyurethane-forming composition is not applied. In addition, in some cases, the backing may be completely removed, as disclosed in US Pat. No. 4,286,003, incorporated herein by reference, so that the polyurethane recombination cushion may directly contact the bottom (see FIGS. 25, 26 and 27).

Also, US Pat. Appl. No. 09 / 513,020, filed, for example, under the name "Carpet Tiles and Carpet Tile Fixtures without Adhesives," issued February 25, 2000, incorporated herein by reference, uses an adhesive. Carpets and methods have not been described.

It is preferred that the tuft module carpet or modular carpet tile of the invention have at least four layers of first backing, latex pre-coat adhesive, hot melt adhesive, fiber glass, recombination foam and felt (see FIG. 14A), but these By removing or replacing one or more of the layers, one can still be designed to have the desired properties or properties. For example, the latex pre-coat adhesive layer can be replaced with a bitumen hot melt layer (see FIG. 20), and the felt layer removed on a free lay (no bottom adhesive) installation product (FIGS. 25, 26 and 27). Glass layer may be removed (see FIGS. 21 and 26).

Referring to FIG. 22, the carpet structure may include two or more layers of recombination foam. In particular, the foam backing of FIG. 22 includes a fiber glass layer sandwiched between two recombination foam layers, and a bottom felt backing. Such foam composites may be formed by flame stacking layers one by one (see FIGS. 31 and 38).

Referring to FIG. 36, woven carpet structure or article 3610 includes woven material 3620 attached to recombination foam layer 3788 by adhesive or pre-coat 3624. In addition, the backing material 3670 is attached to the foam layer 3678 by, for example, flame lamination.

Referring to FIG. 37, the nonwoven carpet structure or article 3710 includes a nonwoven material 3734, two adhesive layers 3760, a scrim material 3738, a reinforcing material 3758, a recombination foam layer 378 and a backing material. (3758). Adhesive layer 3760 attaches nonwoven fabric 3734 to backing composites 3758, 3778, and 3770 (see FIGS. 31 and 32).

As shown in FIG. 38, the backing material (or composite) 170 may be attached to the bottom of the recombination foam layer 178, and the carpet 112 may be heat or flame (flame lamination) to form the recombination foam layer ( 178) to form a carpet structure or article as shown, for example, in FIGS. 16A, 16B, 20, 21 and 36. Carpet 112 may or may not include pre-coat layer 124 and may be tufted, bonded, woven, nonwoven, or the like.

With reference to FIGS. 33 and 34, a conventional filled polyurethane foam foam carpet tile cushion comprises open cell or substantially open cell polyurethane foam formed by mechanical foaming and thermal curing (see FIG. 33).

Preferred recombination foam materials, such as the small chip size, high density polyurethane recombination foam of the present invention, have a reticulated or skeletal structure with substantially all of the cell walls ruptured (see FIG. 34). 33 and 34 are micrographs of the cross section taken at about 30 times magnification.

In accordance with the present invention, it has unexpectedly been found that small chip sizes, high density recombination foam layers or sheets provide superior cushioning backing carpet tile structures compared to conventional filled polyurethane foams. In addition, carpet tiles comprising such layers of recombination foam have unexpectedly been found to exhibit excellent comfort, wear resistance, durability, sound absorption, cushioning, elasticity, appearance, feel, seamability, and the like. In other words, carpet tiles comprising such recombination foam had a quality equivalent to or greater than that of conventional carpet tiles including filled polyurethane foam or other conventional foams or cushions.

Referring to FIG. 35, tufted carpet tiles of the present invention comprising polyurethane recombination foam had a quality equivalent to or greater than that of conventional tufted carpet tiles including polyurethane. In addition, these two cushion tiles had a better quality than hardback tiles. The cushion backing not only protects the surface of the tile, but also contributes to providing comfort, sound absorption and anti-fatigue properties of the sole.

As shown in FIG. 41, components similar to those described above are indicated by corresponding reference numerals within the 4100 band, and the carpet structure 4110 is incorporated into the adhesive layer 4187 and the bottom surface of the multicomponent or composite backing. It is designed to include the sheet or layer 4190.

Magnetic sheet 4190 provides peelable adhesion of the carpet composite or tile 4110 to, for example, a metal embossed adjacent floor or floor panel. The magnetic sheet may be attached to the backing material (second backing) 4170 by one or more adhesive layers 4187, such as a hot melt adhesive or an adhesive on a self-stick magnetic sheet material. Preferably, the magnetic sheet or layer 4190 is a flexible magnetic material, such as strontium ferrite (about 80 to 97%) and binder (about 20 to 3%), made of magnetic material or magnetized by passing it through a strong magnet. Do. Such materials are available from Flexmag Industries of Marriott, Ohio. In this embodiment it is preferred that the magnetic sheet or layer 4190 is continuous, but the magnetic material may be a strip, a piece or a tape.

U.S. Patent 4,397,900 describes magnetic carpet tiles (and methods) having strips of magnetic material buried in a PVC layer, which is incorporated herein by reference. In this patent, a strip of magnetic material is placed on a conveyor and a PVC layer is molded thereon.

In accordance with one embodiment of the present invention, the magnetic sheet or layer 4190 is part of a composite backing (backing material 4170, hot melt 4187 and magnetic sheet 4190) and is applied to the hot melt or adhesive layer 4417. Is adhered to the foam or cushion layer 4178.

According to another embodiment of the present invention, the magnetic sheet or layer 4190 already has an adhesive 4187 on one side with the adhesive side facing up and adhered to the backing material 4170 by pressure and / or heat.

In addition, although the multicomponent backings of FIGS. 41-43 are shown with respect to the loop pile tuft carpet structure, such composite backings may be combined with any tuft or bond carpet structure, or other surface textiles or materials such as woven, knitted or nonwoven. It can be appreciated that it can be used in connection with.

According to another embodiment shown in FIGS. 42-45, a hot melt or adhesive layer may be used to bond the first carpet to the cushion layer with or without reinforcement material. The carpet composite or tile 4200 of FIGS. 42 and 43 includes a bottom hot melt or adhesive layer having one or more strips of magnetic material embedded therein, the one or more strips of magnetic material such as the magnetic sheet of the carpet composite 4110. The carpet is releasably attached to a metal floor, a metal embossed adjacent floor, or an embossed floor panel. Preferably, the magnetic strip of FIGS. 42 and 43 is a flexible magnetic strip that provides flexibility at least in the longitudinal direction.

The flexible magnetic strip may be made of strontium ferrite in the binder, styrene butyldiene-based thermoplastics with embedded magnetic particles, or similar materials that provide sufficient support to the metallic surface on which the tile is placed. Preferably, the magnetic strip is provided in a roll and embedded in a hot melt adhesive layer attached to a foam layer (recombinant foam) to form a cushioning backing carpet composite or tile having a magnetic strip on the bottom surface.

44 and 45 relate to further structures 4300 and 4400, respectively, with a bottom coating or film layer, such as a hot melt or adhesive layer, as the bottom surface. This bottom coating or film layer provides additional adhesion to the bottom and protects the bottom surface of the foam layer (recombinant foam). This bottom coat or film layer may be applied with a roll coater such as a spray coater, knife coater or three roll coater, or alternatively laminated to a foam layer. It is preferable that this bottom coating or film is relatively thin and flexible. The bottom cladding or film layer may be embossed or woven to increase friction with the floor, such as embossed adjacent panels or concrete surfaces, to more easily improve the adhesive-free installation of the tile. Such friction coatings are acrylics, urethanes, any adhesives that dry to " soft hands " to form friction coatings, any peelable adhesives, any sticky or sticky adhesives, resins or polymers, and the like.

In addition, although the coated or laminated backings of FIGS. 44 and 45 are shown with respect to the loop pile tuft carpet structure, such backing may be any tuft or bond carpet structure, or any surface material such as woven, knitted or nonwoven or It can also be used in conjunction with textiles.

Another additional feature of the present invention is the incorporation of recombination or regeneration products into the general market. As shown in Figs. 28 to 30, recombination allows the manufacturer to obtain waste polyurethanes (typically furniture fillers, wastes generated during the manufacture of raw materials, etc.), which are then compressed or crushed into chips of specific sizes. The process involves injecting pure urethane and re-bonding the chips to form a large chunk of compressed urethane.

In accordance with the present invention, usually urethane chips are low density variants of, for example, one to three pounds per cubic foot and may contain small amounts of high density foam hard pieces. After compression and adhesion, the density is increased to more than 15 pounds / cubic feet. This mass is then cut, split or peeled into roll lengths of any thickness. The length of the foam is then adjusted to the flame laminator and the second nonwoven fabric and the glass is bonded to each side of the recombination cushion and rolled again. The only required step at this point is the use of lamination or hot melt adhesive on the pre-coated tuft carpet of the composite, with the result that a cushion tile with waste or recycled foam is obtained.

In the case of recombined carpet tiles, the inventors have found that it is desirable to use a range of densities and thicknesses as narrow as possible with other cushion backing carpet tiles and to substantially reduce the size of the chip. Reduced chip size makes the foam backing more beautiful, stronger and more uniform.

According to one specific embodiment of the invention, commercial grade cushion carpet tiles are prepared using preformed recombination foam or filler. The recombination filler of about 13 lb / ft ³ density is modified to have a bonded nonwoven material on each of its upper and lower surfaces. This composite recombination filler has a thickness of about 0.25 ", split in half to create two foam backings, each about 0.125" thick, with nonwoven material attached to one surface. Each backing is then directly bonded to either the pre-coated tufted carpet or the latex based binding carpet using a hot melt adhesive and then cut to prepare the tiles.

There are some additional alternative methods of laminating structures to the recombination material in the composite of the present invention. For example:

1. The nonwoven and / or glass may first be bonded to the recombination foam (urethane) by flame lamination, and then the composite may be laminated to the carpet using an adhesive. This adhesive can be hot melt in many properties, or it can be a reactive or water-based urethane.

2. In addition, the composite film can be laminated using an adhesive film.

3. The composite may be laminated to the recombination foam using urethane, water based adhesive or hot melt. This lamination can be performed off-line to form a composite, or in-line operation with carpet being laminated to the composite.

Other methods of laminating the structure to urethane foam, such as using photoreactive materials, are also possible.

Recombinant foam is produced in several ways, for example, by forming a compressed cylindrical log and dividing or cutting it to form a sheet, or by forming a rectangular block or mass and cutting or cutting it to form a sheet, or other placement method or continuous It may be prepared by a method such as extruding chips and binders, compressing the extrudate and curing the compacted extrudate. According to one continuous manufacturing method of the present invention, the chips and binder are mixed together and placed between the backing material and the reinforcing material, and then compressed, set or cured.

The following table shows examples of exemplary embodiments or foam layer specifications of the present invention:

A. Commercial Carpet Tile Recombination Foam Specification

Foam weight 14.5 oz / yd ² Foam density 8 lbs./ft ³ Foam Thickness (Preliminary Lamination) 4mm Uncompressed Chip Size 7 mm Chip material Polyurethane foam Binder or Prepolymer 15 wt% chip 82 to 85 wt% Binder material Polyurethane prepolymer Compression ratio 3: 1 Colorant (possible addition) About 3% Milliken Reactint Polyurethane Colorant

B. Commercial Carpet Tile Recombination Foam Specification

Foam weight 14.5 oz / yd ² Foam density 8 lbs./ft ³ Foam Thickness (Preliminary Lamination) 2 mm Uncompressed Chip Size 7 mm Chip material Polyurethane foam Binder or Prepolymer 15 wt% chip 82 to 85 wt% Binder material Polyurethane prepolymer Compression ratio 3: 1 Colorant (possible addition) About 3% Milliken Reactant Polyurethane Colorant

C. Residential / Hospital Carpet Tile Recombination Foam Specification

Foam weight 14.5 oz / yd ² Foam density 8 lbs./ft ³ Foam Thickness (Preliminary Lamination) 7 mm Uncompressed Chip Size 7 mm Chip material Polyurethane foam Binder or Prepolymer 15% chip 82 to 85% Binder material Polyurethane prepolymer Compression ratio 3: 1 Colorant (possible addition) About 3% Milliken Reactant Polyurethane Colorant

D. Commercial Carpet Tile Recombination Foam Specification Range

Foam weight 7 to 50 oz / yd ² Foam density 4 to 16 lbs./ft ³ Foam Thickness (Preliminary Lamination) 2 to 7mm Uncompressed Chip Size 2 to 14mm Chip material Polyurethane Foam (Polyester or Polyether) Binder or Prepolymer 5 to 20% chip 60 to 95% Binder material Polyurethane prepolymer (polyester or polyether) Compression ratio 2: 1 to 5: 1 Additives such as colorants, fibers, fillers, etc. 0 to 20%

E. Desired Commercial Carpet Tile Recombination Foam Specification Range

Foam weight 10 to 18 oz / yd ² Foam density 7 to 12 lbs./ft ³ Foam Thickness (Preliminary Lamination) 3 to 5mm Uncompressed Chip Size 5 to 8mm Chip material Polyurethane Foam (Polyester or Polyether) Binder or Prepolymer 12 to 17% chip 78 to 88% Binder material Polyurethane prepolymer (polyester or polyether) Compression ratio 3: 1 Additives such as colorants, fillers, fibers, etc. 0 to 5%

F. Residential / Hospital Carpet Tile Recombination Foam Specification Range

Foam weight 7 to 84 oz / yd ² Foam density 4 to 16 lbs./ft ³ Foam Thickness (Preliminary Lamination) 2 to 10mm Uncompressed Chip Size 2 to 14mm Chip material Polyurethane Foam (Polyester or Polyether) Binder or Prepolymer 5 to 20% chip 60 to 95% Binder material Polyurethane prepolymer (polyester or polyether) Compression ratio 2: 1 to 5: 1 Additives such as colorants, fillers, fibers, etc. 0 to 20%

G. Desired Residential / Hospital Carpet Tile Recombination Foam Specification Range

Foam weight 10 to 28 oz / yd ² Foam density 6 to 10 lbs./ft ³ Foam Thickness (Preliminary Lamination) 5 to 8mm Uncompressed Chip Size 5 to 8mm Chip material Polyurethane Foam (Polyester or Polyether) Binder or Prepolymer 12 to 17% chip 83 to 88% Binder material Polyurethane prepolymer (polyester or polyether) Compression ratio 3: 1 Additives such as colorants, fillers, fibers, etc. 0 to 5%

H. Carpet Tile Recombination Foam Specification

Foam weight 14.5 oz / yd ² Foam density 8 lbs./ft ³ Foam Thickness (Preliminary Lamination) 4mm Uncompressed Chip Size 7 mm Chip material Polyurethane foam Binder or Prepolymer 15% chip 80 to 85% Binder material Polyurethane prepolymer Compression ratio 3: 1 Additives such as fillers, colorants, fibers, etc. 0 to 5%

I. Flame-Laminated Carpet Tile Recombination Foam Specification

Foam density 9 lbs./ft ³ Foam Thickness (Preliminary Lamination) 4 to 4.5mm Uncompressed Chip Size 7 mm Chip material Polyurethane Foam (at least 25% polyester) Binder or Prepolymer 10 to 15% chip 85 to 90% Binder material Polyurethane prepolymer Compression ratio 3: 1

J. Hot Melt Laminated Carpet Tile Recombination Foam Specification

Foam density 9 lbs./ft ³ Foam Thickness (Preliminary Lamination) 4mm Uncompressed Chip Size 7 mm Chip material Polyurethane foam (100% polyester is possible) Binder or Prepolymer 10 to 15% chip 85 to 90% Binder material Polyurethane prepolymer Compression ratio 3: 1

K. Carpet Tile Recombination Foam Specification

Foam weight 14.5 oz / yd ² Foam density 8 lbs./ft ³ Foam Thickness (Preliminary Lamination) 4mm Uncompressed Chip Size 7 mm Chip material Polyurethane foam Binder or Prepolymer 10 to 20% chip 80 to 90% Binder material Polyurethane prepolymer Compression ratio 3: 1 Additives (colorants, fillers, antibacterial agents, flame retardants, antifungal agents, solid particles, etc.) 0 to 10%

L. Wide Carpet Recombination Foam Specification

Foam weight 14.5 oz / yd ² Foam density 8 lbs./ft ³ Foam Thickness (Preliminary Lamination) 7 mm Uncompressed Chip Size 7 mm Chip material Polyurethane foam Binder or Prepolymer 15% chip 82 to 85% Binder material Polyurethane prepolymer Compression ratio 3: 1 coloring agent Milliken Reactant Polyurethane Colorant (about 3%)

U. S. Patent No. 5,929, 145 describes bitumen backing carpet tiles and bitumen compositions suitable for carpet tile backing layers and are incorporated herein by reference.

The foam backing or cushioning backing carpet composites, carpet products or carpet tiles of the invention are preferably sound absorbing, especially for increased access floors, reduced drum head noise, comfort, durability, anti-fatigue, cushioning, good design or pattern Print registration, hidden junctions, regeneration content, and the like.

According to one production process of the present invention, the latex pre-coat is replaced with a hot melt pre-coat as shown in FIGS. 6A, 6B, 7A, 7B and 39, and also shown in FIGS. 10A, 10B, 39 and 40. It is replaced with a backing layer attached to the foam by an adhesive as shown.

In one embodiment, the first hot melt coating or pre-coat is directed to a carpet having some type of physical operation that compresses the hot melt into a yarn bundle before cooling. The hot melt rises very rapidly when cooled. This coater is a roll coater in which the roll directly rotates the back side of the yarn and pushes the coating into the yarn, or a curtain coater having a static rod on the roll or pushing the coating into the yarn. The hot melt blend viscosity is as low as possible and ranges from about 200 to 5000 cps. This low viscosity was achieved by excluding filler from the hot melt blend. When filler is still present as a hot melt and the viscosity is low, "filler exclusion" becomes a problem. The hot melt is then constantly circulated in some way to prevent the filler from settling.

Immediately after the coating is pushed into the yarns, the cooling roll compresses the yarns flat while simultaneously cooling the hot melt to keep the giant yarns flat. This minimizes the amount of pre-coat and the amount of subsequent coating required. At the same nip point, or using a cooling drum, a layer of nonwoven glass reinforcement is laminated to the pre-coated carpet. The application rate for the hot melt pre-coat is about 10 to 50 oz / yd ² , preferably about 10 to 20 oz / yd ² .

This coated / laminated carpet composite then proceeds to a hot melt coater to apply a very lightweight and high viscosity hot melt adhesive layer. The blend may again be a modified hot melt adhesive that must be high in viscosity to prevent the hot melt from penetrating into the recombination foam. This modification is achieved by reducing the particle size of the filler or adding crushed carpet waste. The viscosity is raised by increasing the surface area of the filler or by introducing fibers into the compound. The ideal viscosity is about 50,000 to 200,000 cps. The adhesive layer hot melt application rate is about 3 to 8 oz / yd ² , preferably about 5 oz / yd ² . It should be a lightweight coating applied to the glass side of the carpet laminate. It consists of a curtain coater, an engraved roll or a doctor blade roll. The coater can be fed using a small extrusion machine to add recycled carpet waste while increasing the viscosity. After applying this lightweight coating at high viscosity, the recombination foam can be laminated again to the carpet / glass composite around the cooling drum.

The third and last hot melt coater is an engraving roll that directly coats the recombination foam and then applies a nonwoven or coats the nonwoven backing layer and compresses the composite into the coating. The formulation for this hot melt adhesive application is the same as the adhesive between the glass and the recombination foam because minimal penetration into the foam is desired. Curtain coverings for nonwoven surfaces are also contemplated. Carpet waste is introduced again. The application rate and viscosity are the same as the other hot melt adhesive layers (FIGS. 39 and 40).

Flame lamination is preferred over cladding for bonded cushion wide carpet products to allow the composite to rotate.

In the hot melt pre-coat process, it is preferred that the polyester first backing or the heat stabilized first backing withstand the heat from the hot melt pre-coat.

In addition, although the invention may be understood with reference to the following examples, these examples do not limit the invention as defined and interpreted in terms of the appended claims.

Example 1

Tufted carpet is made by the apparatus and method as illustrated and described in connection with FIG. 2. The carpet has the arrangement illustrated and described in connection with FIG. 3A. The production variables are as follows:

Yarn: 15 oz / yd ² , nylon 6,6 loop pile continuous filament;

First backing: 4 oz / yd ² , nonwoven polyester;

Pre-coat: SBR latex filled with 16 oz / yd ² , 100 parts CaCO ₂ ;

Hot melt adhesive: 42 oz / yd ² , modified polypropylene;

Laminates;

Reinforcement: 2 oz / yd ² , nonwoven glass with acrylic binder;

Urethane recombination foam Application range: 20 oz / yd ² ;

Urethane recombination foam density: 16 lbs./ft ³ ;

Backing material: 4 oz / yd ² , nonwoven (50% polypropylene and 50% polyester).

Example 2

Structure: Tufted Fabric Loop Pile;

Surface fiber: 100% Milliken Certified WearOn® nylon;

Solid prophylactic agents: MilliGuard (registered trademark);

Antimicrobial agents: BioCare (registered trademark);

Staining method: Millitron (registered trademark) dye injection printing;

Gauge: 1/10 inch (39.4 / 10 cm);

Joules: 14.4 / inch (56.7 / 10 cm);

Tuft: 143.9 / inch ² (2230.3 / 100 cm ² );

Standard backing: PVC-less underscore (UNDERSCORE® brand) cushions;

Nominal total thickness: 0.34 inch (8.6 mm);

Total weight: 99.9 oz / yd ² (3,387.4 g / m ² );

Tile size: 36 x 36 inches (914.4 x 914.4 mm);

Flammability (Radiant Panel ASTM-E-648): 0.45 or more (type I);

Smoke density (NFPA-258-T or ASTM-E-662): 450 or less;

Metheneamine pill test (CPSCFF-1-170 or ASTM D 2859): self-extinguishing;

Light fastness (AATCC 16E): 4.0 or more at 80 hours;

Color fastness to friction (AATCC 165): at least 4.0 wet or dry;

Static electricity (AATCC-134) 20% relative humidity, 70 ° F .: 3.5 KV or less;

Dimensional stability-Aachener test (DIN standard 54318): 0.2% or less;

Recommended trade: very commercial;

Recommended Care: MilliCare (registered trademark);

CRI Indoor Air Quality: Product Type: 12200793;

Foam: Recombination foam.

Example 3

Structure: Tufted Fabric Loop Pile;

Surface fiber: 100% Milliken Certified wear on (registered trademark);

nylon;

Solid prophylactic protective agents: milligard (registered trademark);

Antibacterial: biocare (registered trademark);

Staining method: milltron dyeing injection printing;

Gauge: 1/10 inch (39.4 / 10 cm);

Joules: 14.4 / inch (56.7 / 10 cm);

Tuft: 143.9 / inch ² (2230.3 / 100 cm ² );

Standard backing: PVC-less underscore® cushion;

Nominal total thickness: 0.34 inch (8.6 mm);

Total weight: 99.9 oz / yd ² (3,387.4 g / m ² );

Tile size: 36 x 36 inches (914.4 x 914.4 mm);

Flammability (radiant panel ASTM-E-648): 0.45 or more (type I);

Smoke density (NFPA-258-T or ASTM-E-662): 450 or less;

Metheneamine peel test (CPSCFF-1-170 or ASTM D 2859): self-extinguishing;

Light fastness (AATCC 16E): 4.0 or more at 80 hours;

Color fastness to friction (AATCC 165): at least 4.0 wet or dry;

Static electricity (AATCC-134) 20% relative humidity, 70 ° F .: 3.5 KV or less;

Dimensional stability-arkener test (DIN standard 54318): 0.2% or less;

Recommended trade: very commercial;

Recommended Care: MilliCare (registered trademark);

CRI Indoor Air Quality: Product Type: 12200793;

Foam: Recombination foam.

Example 4

Tufted carpet is made by the apparatus and method as illustrated and described in connection with FIG. 2. The carpet has the arrangement illustrated and described in connection with FIG. 3A. The production variables are as follows:

Yarn: 29 oz / yd ² , nylon 6,6 loop pile continuous filament, white, 1350 denier, unjoined, not twisted, not heat treated;

First backing: 4 oz / yd ² , nonwoven polyester;

Pre-coat: SBR latex filled with 16 oz / yd ² , 100 parts CaCO ₂ ;

Hot melt adhesive: 36 oz / yd ² , modified polypropylene;

Laminates;

Reinforcement: 2 oz / yd ² , nonwoven glass with acrylic binder;

Urethane recombination foam Application range: 15 oz / yd ² ;

Urethane recombination foam density: 16 lbs./ft ³ ;

Backing material: 4 oz / yd ² , nonwoven (50% polypropylene and 50% polyester).

Example 5

Tufted carpet is made by the apparatus and method as illustrated and described in connection with FIG. 2. The carpet has the arrangement illustrated and described in connection with FIG. 3A. The production variables are as follows:

Yarn: 24 oz / yd ² , nylon 6,6 loop pile continuous filament;

First backing: 2 oz / yd ² , nonwoven polyester;

Pre-coat: 14 oz / yd ² , SBR latex filled with 100 parts CaCO ₂ ;

Hot melt adhesive: 38 oz / yd ² , modified polypropylene;

Laminates;

Reinforcement: 3 oz / yd ² , nonwoven glass with acrylic binder;

Urethane recombination foam Application range: 22 oz / yd ² ;

Urethane recombination foam density: 9 lbs./ft ³ ;

Backing material: 2 oz / yd ² , nonwoven (50% polypropylene and 50% polyester).

Example 6

Tufted carpet is made by the apparatus and method as illustrated and described with reference to FIG. 5. The carpet has the arrangement illustrated and described with respect to FIG. 6A. The production variables are as follows:

Yarn: 40 oz / yd ² , nylon 6,6 loop pile;

First backing: 4 oz / yd ² , nonwoven polyester;

Laminates;

Reinforcement: 2 oz / yd ² , nonwoven glass with acrylic binder;

Urethane recombination foam Application range: 36 oz / yd ² ;

Urethane recombination foam density: 16 lbs./ft ³ ;

Backing material: 4 oz / yd ² , nonwoven (50% polypropylene and 50% polyester).

Example 7

Tufted carpet is made by the apparatus and method as illustrated and described in connection with FIG. 19. The carpet has the arrangement illustrated and described in connection with FIG. 18. The production variables are as follows:

Yarn: 15 oz / yd ² , nylon 6,6 loop pile continuous filament, white, 1350 denier, unjoined, not twisted, not heat treated;

First backing: 4 oz / yd ² , nonwoven polyester;

Pre-coat: SBR latex filled with 16 oz / yd ² , 100 parts CaCO ₂ ;

Reinforcing material: 2 oz / yd ² , non-woven glass comprising acrylic binder;

Urethane recombination foam Application range: 20 oz / yd ² ;

Urethane Recombinant Foam Density: 16 lbs./ft ³ .

In one study of 64 for assessing carpet tiles for walking and standing comfort, the recombination foam comprising the bonded carpet tiles of the present invention comprises a bonded carpet tile or a conventional bonded hard backing carpet tile (same surface). Was more comfortable than conventionally filled polyurethanes (greater than 75% of participants who evaluated recombination tiles as the best choice for comfort).

In another survey of more than 75 participants, the best choice for comfort was recombination foam comprising carpet tiles (thickness 7 mm, density 9 lb., chip size 7 mm, compared to conventionally filled polyurethanes comprising carpet tiles). Polyurethane recombination foam), recombination foam containing foamless foam tiles (thickness 4 mm, density 9 lb., chip size 7 mm, polyurethane), recombination foam containing foamless tiles (thickness 2 mm, density 9 lb, chip) Size 7 mm, polyurethane), and finally conventional vinyl hard carpet tiles (same surface). In this study, about 89% chose the thickest recombination foam tile as the most comfortable and about 11% chose the intermediate recombination foam tile as the most comfortable.

Test Method Performed ASTM D-5252 Hexapod Drum Tester ISO / TR 10361 hexaford tumbler Rating based on CRI TM-101 photo measurement

Device: WIRA INSTRUMENTATION Hexaford Tumbler Carpet Tester Procedure

Test samples (same surface and cushion thickness as the recombination cushion backing carpet tiles of the present invention, standard Milliken Comfort Plus® cushion backing carpet tiles) were introduced into the reported cycles of "hexapod" tumbling and vacuumed. Samples are removed every 2,000 cycles for recovery.

Four times were performed back and forth along the length of the sample using an Electrolux upright vacuum cleaner (Found II).

Samples were evaluated using vertical illumination (1500 lux) corresponding to daylight. Samples were observed at 45 ° C. at a distance of 1½ m and screened in all directions.

Number of cycles in hexaford 4000 12000 Description of the rating Color change 4 to 4.5 3 to 3.5 5: ignore or no change 4: slight change Overall appearance 4 3 3: moderate change 2. Significant change 1: serious change

Comfort rating

1. Gmax-Max simulates footsteps on the surface. The measurement is described as a multiple of "g" (gravity) or Gmax. The smaller the value, the smaller the impact force and the more comfortable the product feels under the feet. The higher the value, the greater the impact and the less comfortable the carpet.

Gmax test results

Standard Milliken Comfort Plus® cushion backing carpet tiles-116;

Recombination cushion backing carpet tiles of the invention (same surface and cushion thickness as standard Milliken Comfort Plus® cushion backing carpet tiles) -121;

Standard commercial wide carpet-185 without underlayment;

Standard hard carpet tiles such as Everwher PVC cover-227.

Resilience Reviews / Fried Balls

Cushion Resilience-Cushion Resilience measures the percent bounce of a metal ball when it falls from a reference height. This exhibits the shock absorbing properties of the cushion which helps to reduce the visual wear of the carpet side. The higher the value, the higher the% bounce and the more resilient the cushion.

Resilience Results

Standard Milliken Comfort Plus® cushion backing carpet tiles-30;

Recombined polyurethane cushion backing carpet tiles of the invention (same surface and cushion thickness as standard Milliken Comfort Plus® cushion backing carpet tiles) -29;

Standard commercial wide carpet-17 without underlayment;

Standard hard carpet tiles-13.

Maintain appearance

Appearance Retention Assessment (ARR)-ARR values are exposed to conditions according to ASTM D-5252 (hexaford) or ASTM D-5417 (Vettermann) test method using the cycle numbers for the short and long term tests described above. It is measured by grading the change in appearance of the carpet.

ARR- weak (short term> / = 3.0, long term> / = 2.5);

ARR- medium (short term> / = 3.5, long term> / = 3.0);

ARR- strong (short term> / = 4.0, long term> / = 3.5).

The recombined foam module carpet tiles of the present invention (same surface and cushion thickness as standard Milliken Comfort Plus® cushion backing carpet tiles) exhibited a short term of about 4.5 and a long term APR of 3.5.

durability

The polyurethane recombination cushion backing carpet tiles of the present invention (same surface and cushion thickness as standard Milliken Comfort Plus® cushion backing carpet tiles) are very long lasting and break more than 25,000 cycles of caster chair tests. It can endure without being.

EN 1307: Classification of file carpets

This criterion classifies carpets into four categories according to their ability to withstand varying degrees of wear.

The categories are as follows:

Class 1: weak use strength (for home use only);

Class 2: Normal (Household or Very Light Shrinkage);

Class 3: strong, eg used in the general contraction range;

Class 4: Very strong, for example in extreme shrinkage range.

Three test methods are included in the classification:

1. Fuzzing or loss-scuff test of mass in the process EN 1963.

2. I (tr) according to EN 1963. The carpet was cut under the backing layer and measured parameters such as surface pile weight, height and density.

I (tr) is a numerical value measured according to an equation including the test measurement.

The higher the required value of I (tr), the higher the kind number.

3. Hexapod or Wetterman drum test for changes in surface appearance, ISO / TR 10361.

Again, the higher the type number, the higher the requirement.

There is also a requirement for a minimum surface pile weight, or surface pile density for shrink-grade carpets.

Such systems are used for carpets with low density piles. There is another system for carpets with high piles.

It is preferred to have carpet composites or tiles with caster chair ratings of greater than 2.3 (test and evaluation method EN 54324). 2.4 or higher is a shrinkage rating.

It is desirable to have carpet composites or tiles with a grade of EN 1307 of more than two.

It is desirable to have a carpet composite or tile with a Herzog walking comfort rating for shrinkage use greater than 0.7 (DIN 54327).

PVC Recombination Foam Filled polyurethane 0.71 0.80 Comfortable walking comfort for home 0.77 0.96 1.04 Comfortable walking comfort 0.97

All tuft loop structures of high value are the most comfortable.

The hexapod test (ISO 10361 Method B) results are 4,000 rotational grades 4.5 (for tufts), 12,000 rotational grades 4.0 (for tufts), 3.5 (total bonds), class 4.

Caster chair test (EN 985) results are 5,000 rotation class 3.0 (tuft), 2.0 (combination), 25,000 rotation class 2.5 (tuft), 2.0 (combination), total value, 2.9 (tuft), 2.4 (combination) to be

Carpet Tiles with Recombinant Foam

Hexaford Recombination Foam (2mm) Recombination Foam (4mm) Recombination Foam (7mm) 2000 cycles 5.0 4.5 5.0 4000 cycles 4.5 4.5 4.5 8000 cycles 4.0 4.0 3.5 12000 cycles 3.0 3.5 3.5 24000 cycles 2.5 3.0 3.0 48,000 cycles 2.5 2.5 3.0 Caster Chair 3.5 3.0 4.5 Gmax 140 104 79.6 Ball fry 29.1 29.5 29.2 Foam test 9 lb.sm. Chip Recombination Foam Filled polyurethane 8 lb.lg. Chip Recombination Foam Compression treatment 7.0% 5.1% 11.8% Compression resistance 2.8 psi 6.5 psi 14.4 psi Each carpet tile surface is 20 oz., Loop pile, 1/8 gauge tuft, nylon 6,6 and the structure is the same as that of FIG. 15A or 19A.

It is apparent that the carpet structure of the present invention can mimic many other structures other than those specifically illustrated and described. Only by way of example, the carpet structures of the present invention have been filed on Feb. 25, 2000, "Adhesive-Free Carpet Tiles and Carpet Tile Installations", incorporated herein by reference. " It may mimic the arrangement as disclosed in co-pending US patent application Ser. No. 09 / 513,020, entitled column. The carpet tiles of the present invention can be manufactured according to stringent manufacturing requirements so that all the edges of the tiles do not have a cup shape of more than 3/16 "and the edges do not have a curl shape of more than 1/16". have. Even more preferably, the edges of all tiles do not have a cup shape of more than 2/16 "or a curl shape of more than 1/32". Each cushion backing carpet tile made in accordance with these specifications can be used to provide a floor covering installation having a plurality of carpet tiles installed without the use of adhesives to properly hold the tiles.

The carpet or carpet tile of the invention is preferably a dimensionally stable cushioned carpet or carpet tile suitable for placement as discrete modular units across a surface, such as a floor surface.

In addition, the carpet or carpet tile of the present invention is preferably sufficiently stable to withstand the rigors of the injection dye printing process without substantial shrinkage, cupping, curling, and the like. Stabilized carpets or carpet tiles of the present invention comprise one or more stabilizing layers, for example fiber glass mats. In addition, they preferably comprise one or more resilient adhesive layers that tend to distribute the load across the carpet or carpet tile, imparting some flexibility to the tile.

Of course, although some potentially preferred embodiments, methods and implementations have been presented, it is obvious that modifications may be made and other aspects of the principles of the invention may occur to those skilled in the art. . Accordingly, the appended claims include any modifications and other embodiments in which the specifics of the invention may be cited within the true principles and scope of the invention.

Claims (150)

A surface coating, such as a wall covering, floor covering, carpeting, or carpet tile, comprising a first carpet and a recombination foam cushion secured below the first carpet. The method of claim 1, And at least one adhesive layer of at least one adhesive material between the first carpet and the recombination foam cushion. The method of claim 1, And a layer of reinforcing material disposed in the mass of adhesive material such that at least a portion of the mass of adhesive material extends away from one or more sides of the layer of reinforcing material. The method of claim 2, Surface coating material wherein the adhesive material comprises at least one of thermoplastic and thermosetting adhesive. The method of claim 1, The surface coating of which the first carpet has a surface weight of about 12 to 60 oz / yd ² . The method of claim 1, A surface coating having a plurality of edges, each having a cup of about 3/16 "or less and a curl of about 1/16" or less. The method of claim 2, A surface coating material wherein the adhesive layer is present at a level of about 100 oz / yd ² or less. The method of claim 2, A surface coating material wherein said adhesive layer is present at a level of about 36 to 90 oz / yd ² . The method of claim 1, And the recombination foam cushion has a density of about 25 lb / ft ³ or less. The method of claim 1, And the recombination foam cushion has a density of about 9 lb / ft ³ or less. The method of claim 1, And the recombination foam cushion has an uncompressed chip size of about 25 mm or less. The method of claim 11, A surface coating material having an uncompressed chip size of about 12 mm or less. The method of claim 11, A surface coating material having an uncompressed chip size of about 7 mm or less. The method of claim 1, And the recombination foam has a binder amount of about 25% or less. The method of claim 14, Surface coating material having a binder content of about 15% or less. The method of claim 14, Surface coating material having a binder content of about 10% or less. The method of claim 2, And the adhesive material comprises a hot melt adhesive. The method of claim 1, The surface coating of which the first carpet has a surface weight of about 55 oz / yd ² or less. The method of claim 17, And the hot melt adhesive is present at a level of about 36 to 50 oz / yd ² . The method of claim 2, And the adhesive material comprises a polyolefin-based thermoplastic hot melt adhesive. The method of claim 1, And the first carpet is at least one of tufted carpet, bonded carpet, flocked carpet, needle perforated carpet, woven carpet. The method of claim 1, And the recombination foam cushion has a thickness of about 25 mm or less. The method of claim 22, Surface coating material with a foam thickness of about 12 mm or less. The method of claim 22, Surface coating material with a foam thickness of about 4 mm or less. The method of claim 2, Surface coating material wherein the adhesive material comprises a polyurethane thermosetting adhesive. The method of claim 1, And the backing foam comprising a backing material bonded to one surface thereof. The method of claim 1, And the first carpet is a tuft carpet comprising a pile yarn, a first backing and a pre-coat adhesive. The method of claim 1, And the first carpet is a tuft carpet comprising a pile yarn and a first backing. The method of claim 1, And the first carpet is a bonded carpet comprising pile yarns and a backing material. The method of claim 3, wherein And the layer of reinforcing material comprises at least one of a porous scrim material, a woven fabric, and a nonwoven fabric. The method of claim 3, wherein A surface coating material wherein the reinforcing material is formed of fiberglass. The method of claim 3, wherein And the reinforcing material comprises a porous textile structure. The method of claim 3, wherein A surface coating material wherein the reinforcing material consists essentially of polyester. The method of claim 3, wherein And the layer of reinforcing material comprises a plurality of glass fibers. The method of claim 3, wherein And the layer of reinforcing material comprises a plurality of polyester fibers. The method of claim 3, wherein The mass of adhesive material substantially penetrates and covers the layer of reinforcing material and extends in a mating relationship between the first carpet and the recombination foam cushion such that the first carpet and the recombination foam cushion are mutually supported by the mass of adhesive material. Surface coating material adhesively bonded. The method of claim 3, wherein And the first carpet is a tufted carpet and the mass of adhesive material extends between the recombination foam cushion and the bottom of the first carpet. The method of claim 3, wherein And the first carpet is a bonded carpet and the mass of adhesive material extends between the recombination foam cushion and the bottom of the first carpet fabric. The method of claim 3, wherein The mass of adhesive material substantially penetrates and covers the layer of reinforcing material and extends in a bonding relationship between the first carpet and the recombination foam cushion such that the first carpet and the recombination foam cushion are covered by the mass of adhesive material. A surface coating material adhesively bonded to each other, the layers of textile backing material bonding to the recombination foam cushion across the recombination foam cushion surface opposite the adhesive material. The method of claim 1, And the recombination foam cushion has a density of about 6 to 12 lb / ft ³ . A first carpet, a polyurethane recombination foam cushion disposed below the first carpet, a mass of adhesive material disposed in a bonding relationship between the first carpet and the recombination foam cushion, and between the first carpet and the recombination foam cushion Wall covering, floor covering, carpeting, comprising a layer of reinforcing material disposed, wherein the layer of reinforcing material is disposed such that at least a portion of the mass of adhesive material extends away from one or more sides of the layer of reinforcing material; Or surface coverings such as carpet tiles. 42. The method of claim 41 wherein And the recombination foam cushion has a density of about 25 lb / ft ³ or less. The method of claim 42, And the first carpet has a surface weight of about 45 oz / yd ² or less. 42. The method of claim 41 wherein And the adhesive material is selected from at least one of thermoplastic and thermoset adhesives. 42. The method of claim 41 wherein Surface coverings that are one or more of carpet tiles, attached cushion wide carpets, and roll products. 42. The method of claim 41 wherein And the polyurethane recombination foam cushion comprises 25% or less polyurethane binder and 50% or more polyurethane foam chips. 42. The method of claim 41 wherein And the polyurethane recombination foam cushion has a density of about 6 to 12 lb / ft ³ . 42. The method of claim 41 wherein A surface coating material wherein the first carpet is a tuft carpet comprising a pile yarn and a first backing. 42. The method of claim 41 wherein A surface coating material in which a textile backing material is disposed across the underside of the polyurethane recombination foam cushion. Bonding the at least one layer of recombination foam to the underside of the first carpet fabric. 51. The method of claim 50 wherein Bonding a reinforcing material between the first carpet and the recombination foam layer. 51. The method of claim 50 wherein Wherein the recombination foam is bound to the carpet by one or more adhesives. 51. The method of claim 50 wherein The recombination foam is bonded to the carpet by lamination. A surface coating prepared by the method of claim 50. Bonding the layer of recombination foam together with the layer of reinforcing material between them to the base of the first carpet fabric. The method of claim 54, wherein And the recombination foam is bonded to the first carpet by at least one adhesive. A carpet composite prepared by the process according to claim 55. A first carpet fabric having a pile face and a first base, the plurality of pile forming yarns projecting outwardly from the pile face; A recombination foam cushion layer disposed below said first carpet fabric; And A layer of stabilizing material having a first side and a second side, the layer of stabilizing material extending substantially in a bonding relationship between the first base and the top side of the recombination foam cushion layer, the far side extending from the first side of the stabilizing material At least one resilient adhesive in contact with the first base, and at least one resilient adhesive extending away from the second side of the layer of stabilizing material and in contact with the top surface of the recombination foam cushion layer. Consisting essentially of a second layer, wherein the stabilizing material layer comprises a crosslinked composite bonded between the first and second layers of a resilient adhesive at a location between the first base and the recombination foam cushion layer. , Dimensional stability cushion carpet tiles suitable for placement as discrete modular units across the floor surface. The method of claim 58, A carpet tile wherein the first carpet fabric is tufted carpet and the first base comprises a layer of adhesive pre-coat extending across the first backing and the underside of the first backing. The method of claim 59, And the adhesive pre-coat comprises at least one of a latex and hot melt adhesive. The method of claim 60, Carpet tiles wherein the hot melt adhesive is a bitumen-based hot melt adhesive. The method of claim 60, A carpet tile wherein the hot melt adhesive is a polyolefin-based hot melt adhesive. The method of claim 58, The carpet tile wherein the resilient adhesive is at least one of thermoset and thermoplastic. The method of claim 58, The carpet tile wherein the first carpet fabric is a combined carpet. The method of claim 58, And the recombination foam cushion layer comprises polyurethane recombination foam having a density of about 5 to 25 lb / ft ³ . The method of claim 58, And the recombination foam cushion layer comprises polyurethane recombination foam having a density of about 5-12 b / ft ³ . The method of claim 58, And the first layer of at least one resilient adhesive comprises a thermosetting adhesive. The method of claim 67 wherein And the adhesive is a bitumen-based hot melt adhesive. The method of claim 67 wherein Carpet tile wherein the adhesive is a polyolefin-based hot melt adhesive. The method of claim 67 wherein A carpet tile wherein the first layer of resilient adhesive is a thermoset adhesive. The method of claim 58, The carpet tile, wherein the first base comprises a first backing and a layer of latex adhesive pre-coat extending across the bottom of the first backing. The method of claim 58, The carpet tile, wherein the first base comprises a layer of hot melt adhesive pre-coat extending across the first backing and the underside of the first backing. The method of claim 58, The carpet tile, wherein the second layer of at least one resilient adhesive comprises a hot melt adhesive. The method of claim 73, wherein And the hot melt adhesive is a bitumen-based hot melt adhesive. The method of claim 73, wherein And the hot melt adhesive is a polyolefin-based hot melt adhesive. The method of claim 73, wherein A carpet tile wherein the second layer of resilient adhesive is a thermoset adhesive. The method of claim 58, At least one resilient first layer and the approximately 100oz / yd ² or less carpet tile combined lumps of two layers of one or more resilient adhesive of the adhesive. The method of claim 58, A carpet tile wherein the stabilizing material comprises a sheet of nonwoven fiberglass. The method of claim 58, A carpet tile in which the first layer of at least one resilient adhesive comprises a hot melt adhesive and the second layer of at least one resilient adhesive comprises a hot melt adhesive. 80. The method of claim 79 wherein A carpet tile wherein the stabilizing material substantially separates the first layer of the one or more resilient adhesives from the second layer of the one or more resilient adhesives. The method of claim 58, The carpet tile further comprising a backing structure disposed across the bottom face of the recombination foam cushion layer. 82. The method of claim 81 wherein A carpet tile in which the backing structure comprises a multicomponent composite. 83. The method of claim 82, And the multicomponent composite comprises a layer of adhesive disposed adjacent the bottom side of the recombination foam cushion layer. 84. The method of claim 83 wherein A carpet tile wherein the layer of adhesive disposed adjacent the bottom side of the recombination foam cushion layer is at a level of about 40 oz / yd ² or less. 82. The method of claim 81 wherein And the backing structure comprises a multicomponent composite comprising a quick release backing. Modifying the recombination foam pads having a density of about 5 to 25 lb / ft ³ so that each nonwoven material is bonded to each of its upper and lower surfaces and the composite recombination pads have a thickness of about 0.25 inches or less; Dividing into two, making two foam backings each having a thickness of about 0.125 inches or less and attaching a nonwoven material to one surface, and using adhesive to bond one or more of the foam backings to tuft carpet and bond carpet Carpet composite manufacturing method comprising the step of binding to one or more of the back. A carpet composite formed by the method of claim 86. A carpet tile comprising a carpet layer and a backing attached thereto and having at least one layer of compressible particles bonded to each other. 89. The method of claim 88 wherein A carpet tile in which the layer of compressible particles bonded to each other has an internal tear strength of at least 3 lbs. 89. The method of claim 88 wherein A carpet tile wherein the layers of compressible particles bonded to each other are compressed particle foam and have a compressibility of less than 100% of the foam thickness at 40 psi. 89. The method of claim 88 wherein Carpet tiles with an appearance retention rating of 4.0 or higher after 4,000 cycles. 92. The method of claim 91 wherein Carpet tiles with an appearance retention rating of at least 3 after 12,000 cycles. 89. The method of claim 88 wherein A carpet tile wherein said layer of compressible particles bonded to each other is at least one of cut, split and exfoliated foam. 89. The method of claim 88 wherein Carpet tile having a regeneration content of at least 85%. 89. The method of claim 88 wherein A carpet tile wherein said layer of compressible particles bonded to each other is an open cell foam made of open cell foam particles bonded to each other. 97. The method of claim 95, Carpet tiles with open cell foam made of foamed polyurethane. 89. The method of claim 88 wherein A carpet tile in which the particles bonded to each other have an average uncompressed chip size of 25 mm or less. 89. The method of claim 88 wherein A carpet tile having a density of 25 lb / ft ³ or less, wherein said layer of compressible particles bonded to each other. 89. The method of claim 88 wherein Carpet tiles having a regeneration content of at least 50%. 89. The method of claim 88 wherein Carpet tiles with hexaford rating greater than 2.0 at 12,000 cycles. 89. The method of claim 88 wherein A carpet tile wherein said layer of compressible particles bonded to each other is a layer of hot melt laminated carpet backing. 89. The method of claim 88 wherein A carpet tile wherein said layer of compressible particles bonded to each other is a layer of flame laminated carpet backing. 89. The method of claim 88 wherein Carpet tiles with an initial Gmax of less than 125. 89. The method of claim 88 wherein Carpet tiles having a cushion weight of less than ³² oz / yd ² and an initial Gmax of less than 125. 89. The method of claim 88 wherein A carpet tile wherein the layers of compressive particles bonded to each other have at least one of honeycomb, reticulated, and skeletal open cell structures. 89. The method of claim 88 wherein A carpet tile having a structure of randomly arranged particles bonded to each other in a state where a layer of compressive particles bonded to each other is compressed. 89. The method of claim 88 wherein Carpet tiles substantially free of fillers in layers of compressible particles bonded to each other. 89. The method of claim 88 wherein A carpet tile in which the compressible particles of the layer of compressible particles bonded to each other are substantially 100% regenerant content. 89. The method of claim 88 wherein Carpet tiles in which compressible particles are bonded to each other with an adhesive. 112. The method of claim 109, A carpet tile wherein the adhesive contains one or more additives, reagents or compounds selected from flame retardants, antibacterial agents, colorants, antimicrobial agents, antibacterial agents, conductive agents, antistatic agents, fibers, fillers, regenerated materials, and combinations thereof. 89. The method of claim 88 wherein Carpet tiles that are bonded to each other while the compressible particles are compressed. 89. The method of claim 88 wherein A carpet tile comprising a plurality of layers of compressible particles bonded to each other. 89. The method of claim 88 wherein A carpet tile having one or more lateral surfaces in which the layers of compressible particles bonded to each other are cut, peeled or divided. 89. The method of claim 88 wherein A carpet tile wherein the carpet layer comprises one or more of woven carpets, tufted carpets, or bonded carpets. 89. The method of claim 88 wherein A carpet tile in which said layers of compressible particles bonded to each other are breathable. 89. The method of claim 88 wherein The carpet tile, wherein the backing is a multilayer backing. 89. The method of claim 88 wherein The carpet tile, wherein the backing comprises a stabilization layer. 89. The method of claim 88 wherein The carpet tile wherein the foam layer has a thickness of less than 8 mm. 89. The method of claim 88 wherein Carpet tiles with a total height of less than 10 mm. 89. The method of claim 88 wherein Carpet tiles with caster chair ratings greater than 2.3. 89. The method of claim 88 wherein Carpet tiles with a rating of EN 1307 greater than 2. 89. The method of claim 88 wherein Carpet tiles with a Herzog walking comfort rating (DIN 54327) greater than 0.70 for shrinkage use. A cushion bag carpet tile comprising a carpet layer and a cushion bag attached thereto, the one having at least one layer of preformed foamed polyurethane particles bonded to each other. 126. The method of claim 123, wherein Cushion bag carpet tile wherein said layer of foamed polyurethane particles bonded to each other has an internal tear strength of at least 3 lbs. 126. The method of claim 123, wherein Cushion back carpet tiles wherein the layer of foamed polyurethane particles bonded to each other has a thickness of about 2 to 20 mm. 126. The method of claim 123, wherein Cushion bag carpet tile wherein said layer of foamed polyurethane particles bonded to each other has a compressibility of less than 100% at 40 psi. 126. The method of claim 123, wherein Cushion bag carpet tiles with an appearance retention rating of 4 or greater in 4,000 cycles. 126. The method of claim 123, wherein Cushion bag carpet tiles with an appearance retention rating of at least 3 in 12,000 cycles. Foam backing carpet tiles with split or exfoliated foam. Foam backing carpet tiles having open cell foam made of expanded polyurethane bonded to each other. 131. The method of claim 130, Foam backing carpet tiles with an average uncompressed particle size of 15 mm or less. Foam backing carpet tiles having a backing of bonded chips of resilient material attached to the textile surface and having a backing density of 14 lb / ft ³ or less. Foam backing carpet tiles with flame laminated foam backing. A foam backing carpet tile having a backing of a bonded chip of resilient material attached to a textile surface and having an initial Gmax of less than 125. 135. The method of claim 134, Cushion backing carpet tiles with a cushion weight of less than 25 lb / ft ³ . Cushion backing carpet tiles having a carpet layer and foam cushion of skeletal structure. Cushioned backing carpet tiles comprising a carpet layer and a backing layer and having a total backing layer weight of less than 50 oz / yd ² . A carpet tile comprising a carpet layer and a backing attached thereto and having at least one layer of foamed open cell particles bonded to each other. Carpet tiles having a cushion weight of less than 25 oz / yd ² and an initial Gmax of less than 125. A carpet tile comprising a carpet layer, a stabilization layer and a backing, wherein at least one of the stabilization layer and the backing has at least one layer of preformed compressible particles bonded to each other. A cushion bag carpet tile comprising a carpet bag, a stabilization layer, and a cushion bag having one or more layers of preformed compressible particles bonded to each other. Carpet tiles having a recycled foam content of at least 50%. Carpet tiles having a recycled foam content of at least 85%. Transforming the foam into compressible particles having an average diameter of less than 25 mm, Mixing the particles with the prepolymer to coat the particles with the prepolymer, Compressing the coated particles at a compression ratio of at least 2: 1, Curing the polymer and fixing the particles in a compressed state to form a recombination foam, And using at least a portion of the recombination foam to form a backing or cushion of carpet tiles, Method of recycling post-production or post-consumer waste foam. A method of making a carpet tile having a backing layer comprising a carpet layer and one or more layers of recombination foam, Forming a backing layer, and Bonding the backing layer to a carpet layer. Carpet surface material, Foam layer, and A cushion bag carpet tile comprising a backing layer comprising magnetic material. 146. The method of claim 146 wherein A carpet tile wherein the magnetic material is either a sheet or a strip. 146. The method of claim 146 wherein The carpet tile wherein the foam layer is a recombination foam. A backing composite for use in surface coatings, such as carpet tiles, comprising a layer of recombination foam suspended between a reinforcing layer and a backing layer. The method of claim 149, wherein And said backing layer are each a woven or nonwoven textile material.