WO2001086056A1 - Carpet underlay system and method - Google Patents
Carpet underlay system and method Download PDFInfo
- Publication number
- WO2001086056A1 WO2001086056A1 PCT/US2001/009665 US0109665W WO0186056A1 WO 2001086056 A1 WO2001086056 A1 WO 2001086056A1 US 0109665 W US0109665 W US 0109665W WO 0186056 A1 WO0186056 A1 WO 0186056A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- carpet
- layer
- scrim
- floor
- intermediate layer
- Prior art date
Links
Classifications
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
- D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
- D06N7/0089—Underlays
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B7/04—Interconnection of layers
- B32B7/06—Interconnection of layers permitting easy separation
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
- B32B5/022—Non-woven fabric
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
- B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
- D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
- D06N7/0071—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing
- D06N7/0081—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing with at least one extra fibrous layer at the backing, e.g. stabilizing fibrous layer, fibrous secondary backing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/10—Inorganic fibres
- B32B2262/101—Glass fibres
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2471/00—Floor coverings
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N2201/00—Chemical constitution of the fibres, threads or yarns
- D06N2201/02—Synthetic macromolecular fibres
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N2201/00—Chemical constitution of the fibres, threads or yarns
- D06N2201/08—Inorganic fibres
- D06N2201/082—Glass fibres
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N2203/00—Macromolecular materials of the coating layers
- D06N2203/04—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
- D06N2203/041—Polyacrylic
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N2209/00—Properties of the materials
- D06N2209/16—Properties of the materials having other properties
- D06N2209/1628—Dimensional stability
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N2209/00—Properties of the materials
- D06N2209/16—Properties of the materials having other properties
- D06N2209/1664—Releasability
Definitions
- This invention relates to a system for easily removing carpet from a floor. More specifically, this invention relates to a carpet underlay system that employs a pair of non-woven sheets in combination with an open scrim material to facilitate removal of a carpet, after installation, from a floor.
- carpeting and an underlying cushion material have been affixed together and also affixed to a floor surface using some type of adhesive. This process is easy for installers to follow, and the carpet requires minimal maintenance after this kind of installation. The frequent heavy loads and forces that are imparted to the carpet require that the carpet be firmly bonded to the floor, to prevent movement and wrinkling of the carpet.
- the cushion materials used beneath carpets have low tensile strength.
- the sponge or foam is torn, and large portions remain stuck to the floor. This problem requires extensive time and effort to fix, as the remaining portions are difficult to remove from the floor. Efforts to solve this problem have met with limited success at best.
- U.S. Patent number 4,647,484, issued to Higgins, teaches an underlay for carpets and especially carpet tiles having a scrim supported, lower foam rubber portion and a Mylar upper portion having adhesive on both sides to provide an attachment to the lower portion and an adhesive upper portion for attachment to a carpet tile.
- the upper adhesive layer is protected by a release paper, which is removed to install carpet tiles thereon.
- An alternate form of the invention eliminates the use of the scrim layer and the bottom layer of adhesive. This apparatus is used for attaching the carpet underlay to the carpet tiles, not for attachment to the floor.
- U.S. Patent number 4,824,498, issued to Goodwin, et al. discloses a sponge cushion material that is suitable for use as a carpet underlay.
- the sponge cushion has a cellular layer bonded to two nonwoven textile layers which can delaminate.
- the carpet is adhesively bonded to the cellular layer and one of the textile layers is adhesively bonded to the floor.
- the carpet can be easily removed by pulling it away from the floor so that the two textile layers delaminate and one of the textile layers remains bonded to the floor.
- the problem with this apparatus is that the cellular layer tends to buckle and wrinkle, especially when the carpet was rolled toward the backing, because the backing is unable to absorb the compressive forces placed on it by being rolled. Such buckling and folding causes indentations in the carpet, which remain visible in the surface of the carpet for extended periods.
- U.S. Patent number 4,853,280 issued to Poteet, teaches a floor covering that may be easily removed from its underlying surface and which resists buckling or folding when rolled, which includes a facing layer, a nonwoven fabric release backing layer on a bottom portion, and a polymer layer bonded to the release backing layer on one side and bonded to the facing layer on the other side.
- the polymer layer of this reference is a blown polyurethane foam layer, which serves as the cushioning portion of the floor covering.
- Patent number 5, 116,439, issued to Raus is directed to a method and apparatus for permitting ready removal of a floor covering through the use of a two-component release web secured between the floor covering and the floor.
- This apparatus discloses a two-layer system, which may be two layers of nonwoven material, or alternatively may be a single layer of scrim combined with a single layer of nonwoven material as a release sheet.
- Figure 1 is a cross sectional view of a scrim layer adhered to an upper surface of an intermediate nonwoven layer, and a release sheet removably adhered to a lower surface of the intermediate nonwoven layer;
- Figure 2 is a cross sectional view of the triple layer carpet underlay system shown in Figure 1 , and further showing a cushion layer on top of the scrim layer, and a carpet layer attached to an upper surface of the cushion layer; and
- Figure 3 is a cross sectional view of the triple layer carpet underlay system shown in Figure 2, further illustrating the separation between the intermediate layer and the release sheet.
- a carpet underlay system 2 is disclosed. Typically, this system will be used in conjunction with a cushion layer and a carpet layer
- the scrim layer 4 in a preferred embodiment, is ultimately attached on its upper side to a cushion layer.
- the intermediate layer 6 is attached directly to an underside of the scrim layer 4.
- the release sheet 8 is removably attached to an underside of the intermediate layer 6.
- the intermediate sheet, attached to an underside of the scrim layer 4, ensures that none of the cushion material sticks to the release sheet 8 either during or after the removal process, serving as a buffer or barrier therebetween.
- the release sheet 8 is a nonwoven fabric, particularly polyester, at a preferred weight of 1.25 ounces per square yard.
- the intermediate layer 6 is also preferably made from polyester having a weight of 0.5 ounces per square yard, and the scrim layer 4 is preferably a fiberglass, tri- axial open scrim.
- Tri-axial scrim is defined as scrim having yarns disposed in three different directions, for example: one warp yarn direction, one weft yarn direction, and one diagonal yarn direction.
- a suitable substitute configuration for the scrim layer 4 would be a square pattern scrim, woven or knit open scrim. Any other suitable material may be used for the scrim layer 4, as long as it imparts dimensional stability to the system.
- Basalt yarns or polyester yarns may be used for the scrim layer.
- An acrylic adhesive is used to bind the nonwoven layers together, although any suitable adhesive may be used, as long as the release sheet 8 is removable from the intermediate layer 6.
- the adhesive used between the scrim layer 4 and the intermediate layer 6 should be significantly stronger than the adhesive between the release sheet 8 and the intermediate (the separable interface).
- the adhesive used between the release sheet 8 and the surface of the floor 14 should be stronger than that used on the separable interface.
- the triple layer carpet underlay system is attached to a cushion member 10 and a carpet layer 12 in a preferred embodiment.
- the scrim layer 4 is attached to the lower side of the cushion member 10, and some portions of the intermediate layer 6 are attached to the cushion member 10 between the holes formed in the scrim layer 4.
- the release sheet 8 or layer is removably attached to the intermediate layer 6, and is permanently attached to the surface of the floor 14.
- the carpet underlay system may be directly attached to the underside of the carpet without a cushion member 10.
- Figure 3 shows the system used with a cushion layer and a carpet layer, where the intermediate layer 6 and all other layers are being separated from the release sheet 8, which remains adhered to the floor surface 14. Because the release sheet is generally a thin fabric, another carpet overlay system may be installed on top of the remaining release sheet, without noticeable effect after the new carpet is installed.
- the intermediate layer and the release sheet may be made from any suitable material, which could be woven or nonwoven, synthetic or natural, or any other material that meets the necessary requirements for operation. Therefore, the spirit and scope of the appended claims should not be limited to the description of the preferred versions contained herein. All features disclosed in this specification may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.
Abstract
Description
Claims
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
AU2001251003A AU2001251003A1 (en) | 2000-05-10 | 2001-03-26 | Carpet underlay system and method |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US56757700A | 2000-05-10 | 2000-05-10 | |
US09/567,577 | 2000-05-10 |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2001086056A1 true WO2001086056A1 (en) | 2001-11-15 |
Family
ID=24267733
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US2001/009665 WO2001086056A1 (en) | 2000-05-10 | 2001-03-26 | Carpet underlay system and method |
Country Status (3)
Country | Link |
---|---|
AU (1) | AU2001251003A1 (en) |
GB (1) | GB2362098A (en) |
WO (1) | WO2001086056A1 (en) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2004085737A2 (en) * | 2003-03-28 | 2004-10-07 | Steven Tasker | Releasable surface covering systems |
Families Citing this family (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB0914377D0 (en) * | 2009-08-17 | 2009-09-30 | Interface Internat B V | Switchable adhesive and objects utilising the same |
Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4647484A (en) | 1983-06-13 | 1987-03-03 | Milliken Research Corporation | Carpet underlay |
US4824498A (en) | 1987-07-09 | 1989-04-25 | James River Corporation | Strippalble sponge cushion underlay for a surface covering, such as carpeting |
US4853280A (en) | 1986-11-17 | 1989-08-01 | The Dow Chemical Company | Releasable polyurethane backed textiles |
GB2228675A (en) * | 1989-02-13 | 1990-09-05 | Sponge Cushion Inc | Floor covering installation and removal |
EP0397390A2 (en) * | 1989-05-11 | 1990-11-14 | The Gates Rubber Company Limited | Carpet underlay |
Family Cites Families (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5082705A (en) * | 1990-07-03 | 1992-01-21 | E. R. Carpenter Company, Inc. | Carpet underlay |
GB2300593B (en) * | 1995-05-12 | 1998-07-15 | Gates | Carpet underlay |
-
2001
- 2001-03-26 WO PCT/US2001/009665 patent/WO2001086056A1/en active Application Filing
- 2001-03-26 AU AU2001251003A patent/AU2001251003A1/en not_active Abandoned
- 2001-04-23 GB GB0109841A patent/GB2362098A/en not_active Withdrawn
Patent Citations (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4647484A (en) | 1983-06-13 | 1987-03-03 | Milliken Research Corporation | Carpet underlay |
US4853280A (en) | 1986-11-17 | 1989-08-01 | The Dow Chemical Company | Releasable polyurethane backed textiles |
US4824498A (en) | 1987-07-09 | 1989-04-25 | James River Corporation | Strippalble sponge cushion underlay for a surface covering, such as carpeting |
GB2228675A (en) * | 1989-02-13 | 1990-09-05 | Sponge Cushion Inc | Floor covering installation and removal |
US5116439A (en) | 1989-02-13 | 1992-05-26 | Sponge-Cushion, Inc. | Method and product for floor covering installation and removal |
EP0397390A2 (en) * | 1989-05-11 | 1990-11-14 | The Gates Rubber Company Limited | Carpet underlay |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2004085737A2 (en) * | 2003-03-28 | 2004-10-07 | Steven Tasker | Releasable surface covering systems |
WO2004085737A3 (en) * | 2003-03-28 | 2005-03-24 | Steven Tasker | Releasable surface covering systems |
Also Published As
Publication number | Publication date |
---|---|
GB2362098A (en) | 2001-11-14 |
GB0109841D0 (en) | 2001-06-13 |
AU2001251003A1 (en) | 2001-11-20 |
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