Method of making composite contoured carpeting

Claim 1

THE METHOD OF MAKING A COMPOSITE CONTOURED CARPET COMPRISING THE STEPS OF APPLYING A SUBSTANTIALLY UNIFORM LAYER OF A POLYETHYLENE POWDER HAVING AN AVERAGE PARTICLE SIZE RANGING FROM ABOUT 200 MESH TO ABOUT 25 MESH IN AN AMOUNT RANGING FROM ABOUT 6 OUNCES TO ABOUT 15 OUNCES PER SQUARE YARD ON THE BACK SURFACE OF A CARPET MATERIAL, SAID POLYETHYLENE HAVING A DENSITY RANGING FROM ABOUT .915 TO ABOUT .940 AND A MELT INDEX RANGING FROM ABOUT 5 TO ABOUT 25, HEATIN SAID POWDER TO AN ELEVATED TEMPERATURE FOR A PERIOD OF TIME SUFFICIENT OF A SOFTENING AND PARTIAL FUSION OF THE POWDER PARTICLES, COMPACTING SAID CARPET MATERIAL AND THE HEAT SOFTENED SAID POWDER THEREON CAUSING IMPREGNATION OF HTE INTERSTICES OF THE BACK SURFACE OF SAID CARPETING MATERIAL AND COALESCENCE OF SAID POWDER INTO A SUBSTANTIALLY UNIFORM COATING, REHEATING SAID COATING TO AN ELEVATED TEMPERATURE FOR A PERIOD OF TIME SUFFICIENT TO EFFECT HEAT SOFTENING THEREOF AND TACKINESS OF THE SURFACE THEREOF, POSITIONING THE HEAT SOFTENED SAID COATING IN INTIMATE CONTACT WITH A PADDING MATERIAL, FORMING SAID CARPET AND SAID PADDING MATERIAL INTO A PRESELECTED CONTOUR, AND THEREAFTER COOLING SAID COATING PROVIDING THEREWITH A COMPOSITE INTEGRALLY BONDED CARPET MATERIAL HAVING A RESILIENT PERMANENT CONTOUR THEREIN.

Claim 2

THE METHOD OF MAKING A COMPOSITE CONTOURED CARPET COMPRISING THE STEPS OF APPLYING A SUBSTANTIALLY UNIFORM LAYER OF A POLYETHYLENE POWDER HAVING AN AVERAGE PARTICLE SIZE RANGING FROM ABOUT 200 MESH TO ABOUT 25 MESH IN AN AMOUNT RANGING FROM ABOUT 6 OUNCES TO ABOUT 15 OUNCES PER SQUARE YARD ON THE BACK SURFACE OF A CARPET MATERIAL, SAID POLYETHYLENE HAVING A DENSITY RANGING FROM ABOUT .915 TO ABOUT .940 AND A MELT INDEX RANGING FROM ABOUT 5 TO ABOUT 25, HEATIN SAID POWDER TO AN ELEVATED TEMPERATURE FOR A PERIOD OF TIME SUFFICIENT OF A SOFTENING AND PARTIAL FUSION OF THE POWDER PARTICLES, COMPACTING SAID CARPET MATERIAL AND THE HEAT SOFTENED SAID POWDER THEREON CAUSING IMPREGNATION OF HTE INTERSTICES OF THE BACK SURFACE OF SAID CARPETING MATERIAL AND COALESCENCE OF SAID POWDER INTO A SUBSTANTIALLY UNIFORM COATING, REHEATING SAID COATING TO AN ELEVATED TEMPERATURE FOR A PERIOD OF TIME SUFFICIENT TO EFFECT HEAT SOFTENING THEREOF AND TACKINESS OF THE SURFACE THEREOF, POSITIONING THE HEAT SOFTENED SAID COATING IN INTIMATE CONTACT WITH A PADDING MATERIAL, FORMING SAID CARPET AND SAID PADDING MATERIAL INTO A PRESELECTED CONTOUR, AND THEREAFTER COOLING SAID COATING PROVIDING THEREWITH A COMPOSITE INTEGRALLY BONDED CARPET MATERIAL HAVING A RESILIENT PERMANENT CONTOUR THEREIN.