US5445860A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Tufted product having an improved backing
Assignee: GFF Holding Co
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Filing: 1994-06-22
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Granted: 1995-08-29
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Expires: 2014-06-22
Abstract
Abstract A method for making tufted carpet, as well as the tufted carpet made by this method, are provided. Pile yarn fibers are tufted into a tufting backing, which is composed of a primary backing, a secondary backing, and an elastomer sandwiched between the primary and secondary backings. In another embodiment, the tufting backing comprises a primary backing and an elastomer applied to the primary backing, but does not include a secondary backing. In a preferred embodiment, the elastomer is applied to the primary backing in a non-contiguous form whereby voids are provided within the arrangement for the tufting backing to be tufted without the primary backing fibers being immobilized. After the pile yarn fibers are tufted into the tufting backing, the elastomer is heated such that it softens, allowing the elastomer to flow in and around the pile yarn fibers. The elastomer may then be cooled, thereby hardening the elastomer and bonding the pile yarn fibers to the primary backing.
Inventors
- 👤 Patrick Bova
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-07 13:02
CPC Classifications
D; D05; D05C; D05C17/00; D05C17/02; D06; D06N; D06N7/00; D06N7/0063; D06N7/0071; D06N7/0076; D06N2201/00; D06N2201/02; D06N2201/0254; D06N2201/0263; D06N2203/00; D06N2203/04; D06N2203/041; D06N2203/042; D06N2203/045; D06N2205/00; D06N2205/04; D06N2207/00; D06N2207/10; D06N2207/14; Y; Y10; Y10T; Y10T428/00; Y10T428/23907; Y10T428/23921; Y10T428/23979; Y10T428/23986
Claims Analysis
Total Claims: 24
Claim 1
Independent Claim
57 words
A tufting backing adapted for tufting pile yarn fibers therethrough, said tufting backing comprising: (a) a primary backing; and (b) an elastomer affixed to a first side of said primary backing, wherein said elastomer is affixed to said primary backing in non-contiguous portions which create at least one void on said first side of said primary backing.
Claim 2
Dependent Claim
57 words
A tufting backing adapted for tufting pile yarn fibers therethrough, said tufting backing comprising: (a) a primary backing; and (b) an elastomer affixed to a first side of said primary backing, wherein said elastomer is affixed to said primary backing in non-contiguous portions which create at least one void on said first side of said primary backing.
Claim 3
Dependent Claim
51 words
The tufting backing of claim 1, wherein said at least one void on said first side of said primary backing is created by affixing said elastomer to said primary backing in non-contiguous portions having shapes selected from the group consisting of: (1) a strand; (2) a dash; and (3) a dot.
Claim 4
Dependent Claim
51 words
The tufting backing of claim 1, wherein said elastomer is affixed to said first side of said primary backing according to the following steps: (i) heating said elastomer to a first specified temperature, whereby said elastomer melts; and (ii) pumping said elastomer on to said first side of said primary backing.
Claim 5
Dependent Claim
24 words
The tufting backing of claim 3, further comprising the following step: (iii) cooling said elastomer at a second specified temperature, wherein said elastomer hardens.
Claim 6
Dependent Claim
13 words
The tufting backing of claim 1, wherein said elastomer comprises a low viscosity.
Claim 7
Dependent Claim
28 words
The tufting backing of claim 3, wherein step (i) further comprises treating said top side of said primary backing for accepting said elastomer prior to said pumping step.
Claim 8
Dependent Claim
23 words
The tufting backing of claim 6, wherein said first side of said primary backing is treated with a corona discharge in step (i).
Claim 9
Dependent Claim
23 words
The tufting backing of claim 6, wherein said first side of said primary backing is treated with a gas flame in step (i).
Claim 10
Dependent Claim
27 words
The tufting backing of claim 3, wherein said elastomer is pumped on to said primary backing in step (ii) through at least one orifice in a die.
Claim 11
Dependent Claim
20 words
The tufting backing of claim 4, wherein said elastomer is cooled with at least one chilled roller in step (iii).
Claim 12
Dependent Claim
21 words
The tufting backing of claim 3, further comprising the step of applying lubricant to said primary backing subsequent to step (ii).
Claim 13
Dependent Claim
19 words
The tufting backing of claim 11, wherein said lubricant is applied to a second side of said primary backing.
Claim 14
Dependent Claim
18 words
The tufting backing of claim 3, further comprising the step of suctioning said elastomer to said primary backing.
Claim 15
Dependent Claim
18 words
The tufting backing of claim 13, wherein said elastomer is suctioned to said primary backing with a vacuum.
Claim 16
Dependent Claim
31 words
The tufting back of claim 1, wherein said primary backing comprises a material selected from the group consisting of a woven polypropylene sheet, a non-woven polypropylene sheet and a jute sheet.
Claim 17
Dependent Claim
13 words
The tufting back of claim 1, wherein said elastomer comprises a thermoplastic material.
Claim 18
Dependent Claim
24 words
The tufting back of claim 16, wherein said thermoplastic material is selected from the group consisting of ethylene/vinyl acetate, ethylene/methyl acrylate and ethylene/ethyl acetate.
Claim 19
Dependent Claim
13 words
The tufting back of claim 1, wherein said elastomer material comprises a filler.
Claim 20
Dependent Claim
20 words
The tufting back of claim 18, wherein said filler is selected from the group consisting of aluminum hydrate and clay.
Claim 21
Dependent Claim
12 words
The tufting back of claim 1, wherein said elastomer comprises a foam.
Claim 22
Dependent Claim
11 words
The tufting back of claim 20, where said foam is azodiacarbonamide.
Claim 23
Dependent Claim
16 words
The tufting back of claim 1, wherein said non-contiguous portions of elastomer comprise a geometric shape.
Claim 24
Dependent Claim
26 words
The tufting back of claim 22, where said geometric shape is selected from the group consisting of a square, a rectangle, a triangle and a circle.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1998-08-28 | 1999-02-27 | 1999-08-29 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2002-08-28 | 2003-02-27 | 2003-08-29 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2006-08-28 | 2007-02-27 | 2007-08-29 | $7700.00 | Window Closed / Lapsed |