US5578357A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Carpet and techniques for making and recycling same
Assignee: TENNESSEE VALLEY PATENT DEVELOPMENT Co
•
Filing: 1994-01-10
•
Granted: 1996-11-26
•
Expires: 2014-01-10
Abstract
Abstract The disclosure relates to a carpet, a process for manufacturing a carpet and a method for recycling a carpet. The carpet of the present disclosure includes a primary backing having tufts of synthetic carpet fibers protruding from a top surface and, optionally, a secondary backing, with an extruded sheet of an isotactic polyolefin polymer between and integrally fused to a bottom surface of the primary backing and an upper surface of the secondary backing. The process for manufacturing the recyclable carpet includes contacting the extruded sheet with the primary backing and, optionally, the secondary backing, at a temperature sufficiently high to integrally fuse the extruded sheet to the respective backing. The method for recycling synthetic carpet of the type described includes manufacturing the carpet, collecting portions of the carpet, and melting the collected portions to make a feedstock.
Inventors
- 👤 Wilbert E. Fink
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-08 22:57
CPC Classifications
B; B32; B32B; B32B37/00; B32B37/14; B32B37/15; B32B37/153; B29; B29B; B29B17/00; B29C; B29C48/00; B29C48/022; B29C48/03; B29C48/07; B29C48/08; B29C48/25; B29C48/88; B29C48/911; B29C48/9135; B29C48/914; B29C48/9175; B29C65/00; B29C65/02; B29C65/40; B29C65/42; B29C66/00; B29C66/01; B29C66/05; B29C66/10; B29C66/11; B29C66/112; B29C66/1122; B29C66/40; B29C66/41; B29C66/45; B29C66/70; B29C66/71; B29C66/72; B29C66/729; B29C66/73; B29C66/737; B29C66/7377; B29C66/73775; B29C66/739; B29C66/7392; B29C66/73921; B29C66/80; B29C66/83; B29C66/834; B29C66/8341; B29C66/83411; B29C66/83415; B29C66/90; B29C66/91; B29C66/912; B29C66/9121; B29C66/914; B29C66/9141; B32B38/00; B32B38/0036; B32B38/004; D; D05; D05C; D05C17/00; D05C17/02; D06; D06N; D06N7/00; D06N7/0063; D06N7/0068; D06N7/0071; D06N7/0076; B29B17/04; B29B17/02; B29B2017/0213; B29B2017/0217; B29B2017/0234; B29K; B29K2105/00; B29K2105/26; B29L; B29L2009/00; B29L2031/00; B29L2031/732; B29L2031/7322; B32B2309/00; B32B2309/02; B32B2309/06; B32B2309/12; D06N2203/00; D06N2203/04; D06N2203/042; D06N2213/00; D06N2213/02; Y; Y02; Y02W; Y02W30/00; Y02W30/50; Y02W30/52; Y02W30/62; Y10; Y10S; Y10S264/00; Y10S264/911; Y10S264/913; Y10S264/92; Y10T; Y10T428/00; Y10T428/23907; Y10T428/23979; Y10T428/23993
Claims Analysis
Total Claims: 32
Claim 1
Independent Claim
88 words
A carpet including at least a tufted primary backing, said tufted primary backing having primary backing and tufts of carpet fibers penetrating a bottom surface of the primary backing and protruding from a top surface of the primary backing; a secondary backing; and an extruded sheet between a bottom surface of said tufted primary backing and an upper surface of said secondary backing, said extruded sheet being integrally fused to said tufted primary backing, and said primary backing, secondary backing and extruded sheet comprising an isotactic polyolefin polymer.
Claim 2
Dependent Claim
88 words
A carpet including at least a tufted primary backing, said tufted primary backing having primary backing and tufts of carpet fibers penetrating a bottom surface of the primary backing and protruding from a top surface of the primary backing; a secondary backing; and an extruded sheet between a bottom surface of said tufted primary backing and an upper surface of said secondary backing, said extruded sheet being integrally fused to said tufted primary backing, and said primary backing, secondary backing and extruded sheet comprising an isotactic polyolefin polymer.
Claim 3
Dependent Claim
28 words
The carpet as claimed in claim 1, wherein said isotactic polyolefin polymer in each of said primary backing, secondary backing and extruded sheet is an isotactic polypropylene polymer.
Claim 4
Dependent Claim
22 words
The carpet as claimed in claim 2, wherein said isotactic polypropylene polymer is a homopolymer; random, impact or block copolymer; or terpolymer.
Claim 5
Dependent Claim
18 words
The carpet as claimed in claim 1, wherein said carpet fibers are integrally fused to said extruded sheet.
Claim 6
Dependent Claim
18 words
The carpet as claimed in claim 1, having a delamination strength of at least 2.5 lb./inch of width.
Claim 7
Dependent Claim
96 words
A recyclable carpet comprising a thermoplastic polyolefin tufted primary backing, said tufted primary backing having a primary backing and tufts of carpet fibers penetrating a bottom surface of the primary backing and protruding from a top surface of said primary backing; and a thermoplastic isotactic polyolefin polymer extruded sheet integrally fused to a bottom surface of the tufted primary backing at a temperature sufficiently high to melt both the tufted primary backing and extruded sheet such that a heat bond is formed between said extruded sheet and at least a portion of said tufted primary backing.
Claim 8
Dependent Claim
96 words
A recyclable carpet comprising a thermoplastic polyolefin tufted primary backing, said tufted primary backing having a primary backing and tufts of carpet fibers penetrating a bottom surface of the primary backing and protruding from a top surface of said primary backing; and a thermoplastic isotactic polyolefin polymer extruded sheet integrally fused to a bottom surface of the tufted primary backing at a temperature sufficiently high to melt both the tufted primary backing and extruded sheet such that a heat bond is formed between said extruded sheet and at least a portion of said tufted primary backing.
Claim 9
Dependent Claim
27 words
The recyclable carpet as claimed in claim 6, wherein said thermoplastic polyolefin polymer in each of said primary backing and said extruded sheet is an isotactic polymer.
Claim 10
Dependent Claim
20 words
The recyclable carpet as claimed in claim 6, wherein said extruded sheet is about 0.5 to about 20 mils thick.
Claim 11
Dependent Claim
36 words
The recyclable carpet as claimed in claim 7, further comprising a thermoplastic polyolefin polymer secondary backing integrally fused to said extruded sheet, wherein said extruded sheet is positioned between said primary backing and said secondary backing.
Claim 12
Dependent Claim
20 words
The recyclable carpet as claimed in claim 9, wherein said primary backing and extruded sheet comprises an isotactic polypropylene polymer.
Claim 13
Dependent Claim
16 words
The recyclable carpet as claimed in claim 10, wherein said secondary backing comprises an isotactic polymer.
Claim 14
Dependent Claim
31 words
The recyclable carpet as claimed in claim 7, further including a second layer integrally fused to a bottom surface of said extruded sheet, wherein said second layer comprises a thermoplastic elastomer.
Claim 15
Dependent Claim
19 words
The recyclable carpet as claimed in claim 6, wherein said carpet fibers are integrally fused to said extruded sheet.
Claim 16
Dependent Claim
20 words
The recyclable carpet as claimed in claim 8, wherein said extruded sheet is about 0.5 to about 15 mils thick.
Claim 17
Dependent Claim
20 words
The recyclable carpet as claimed in claim 8, wherein said extruded sheet is about 0.5 to about 7 mils thick.
Claim 18
Dependent Claim
28 words
The recyclable carpet as claimed in claim 6, wherein said temperature is at least 100° F. higher than the melting point of the thermoplastic polyolefin polymer extruded sheet.
Claim 19
Dependent Claim
28 words
The recyclable carpet as claimed in claim 6, wherein said temperature is at least 125° F. higher than the melting point of the thermoplastic polyolefin polymer extruded sheet.
Claim 20
Dependent Claim
28 words
The recyclable carpet as claimed in claim 6, wherein said temperature is at least 150° F. higher than the melting point of the thermoplastic polyolefin polymer extruded sheet.
Claim 21
Dependent Claim
82 words
A rollable recyclable carpet comprising a tufted primary backing, said tufted primary backing having a primary backing and tufts of carpet fibers penetrating a bottom surface of said primary backing and protruding from a top surface of said primary backing and an extruded sheet integrally fused to a bottom surface of the tufted primary backing at a temperature at or above the melting temperature of the primary backing, wherein both said primary backing and said extruded sheet comprise an isotactic polypropylene polymer.
Claim 22
Dependent Claim
82 words
A rollable recyclable carpet comprising a tufted primary backing, said tufted primary backing having a primary backing and tufts of carpet fibers penetrating a bottom surface of said primary backing and protruding from a top surface of said primary backing and an extruded sheet integrally fused to a bottom surface of the tufted primary backing at a temperature at or above the melting temperature of the primary backing, wherein both said primary backing and said extruded sheet comprise an isotactic polypropylene polymer.
Claim 23
Dependent Claim
28 words
The recyclable carpet as claimed in claim 19, wherein said tufts of carpet fibers protruding from a top surface of said primary backing comprise an isotactic polypropylene polymer.
Claim 24
Dependent Claim
18 words
The recyclable carpet as claimed in claim 20, further including a secondary backing comprising an isotactic polypropylene polymer.
Claim 25
Dependent Claim
20 words
The recyclable carpet material as claimed in claim 21, having a delamination strength of at least 2.5 lb./inch of width.
Claim 26
Dependent Claim
19 words
The recyclable carpet as claimed in claim 19, wherein said carpet fibers are integrally fused to said extruded sheet.
Claim 27
Dependent Claim
19 words
The recyclable carpet as claimed in claim 22, having a delamination strength of at least 6.0 lb./inch of width.
Claim 28
Dependent Claim
19 words
The recyclable carpet as claimed in claim 22, having a delamination strength of at least 6.0 lb./inch of width.
Claim 29
Dependent Claim
120 words
A recyclable carpet including at least a tufted primary backing, said tufted primary backing including a primary backing and tufts of carpet fibers penetrating a bottom surface of the primary backing and protruding from a top surface of the primary backing; a secondary backing; and an extruded sheet between and integrally fused to a bottom surface of said tufted primary backing and an upper surface of said secondary backing, said extruded sheet being integrally fused to said tufted primary backing at a temperature sufficiently high to melt each of the tufted primary backing, extruded sheet and secondary backing such that a heat bond is formed, wherein said primary backing, tufts, secondary backing and extruded sheet comprise an isotactic polypropylene polymer.
Claim 30
Dependent Claim
120 words
A recyclable carpet including at least a tufted primary backing, said tufted primary backing including a primary backing and tufts of carpet fibers penetrating a bottom surface of the primary backing and protruding from a top surface of the primary backing; a secondary backing; and an extruded sheet between and integrally fused to a bottom surface of said tufted primary backing and an upper surface of said secondary backing, said extruded sheet being integrally fused to said tufted primary backing at a temperature sufficiently high to melt each of the tufted primary backing, extruded sheet and secondary backing such that a heat bond is formed, wherein said primary backing, tufts, secondary backing and extruded sheet comprise an isotactic polypropylene polymer.
Claim 31
Dependent Claim
114 words
A rollable, recyclable carpet including at least a thermoplastic polyolefin polymer tufted primary backing, said tufted primary backing having a primary backing and tufts of thermoplastic polyolefin polymer carpet fibers penetrating a bottom surface of the primary backing and protruding from a top surface of the primary backing; and a thermoplastic isotactic polyolefin polymer extruded sheet integrally fused to a bottom surface of the tufted primary backing, said extruded sheet having a thickness of 0.5 to 15 mils and being extruded onto and integrally fused with the tufted primary backing at a temperature at or above the melting temperature of the primary backing, tufts and extruded sheet such that a heat bond is formed.
Claim 32
Dependent Claim
114 words
A rollable, recyclable carpet including at least a thermoplastic polyolefin polymer tufted primary backing, said tufted primary backing having a primary backing and tufts of thermoplastic polyolefin polymer carpet fibers penetrating a bottom surface of the primary backing and protruding from a top surface of the primary backing; and a thermoplastic isotactic polyolefin polymer extruded sheet integrally fused to a bottom surface of the tufted primary backing, said extruded sheet having a thickness of 0.5 to 15 mils and being extruded onto and integrally fused with the tufted primary backing at a temperature at or above the melting temperature of the primary backing, tufts and extruded sheet such that a heat bond is formed.
References Cited (Backward Citations)
GB971958A
Cited
US3309259A
Cited
US3390035A
Cited
US3537946A
Cited
US3551231A
Cited
US3640786A
Cited
US3583936A
Cited
US3562373A
Cited
US3653803A
Cited
US3676280A
Cited
JPS4728438A
Cited
USB501415I5
Cited
US3982051A
Cited
US3887737A
Cited
US3975224A
Cited
US3928281A
Cited
US4028159A
Cited
US4234366A
Cited
US3940525A
Cited
US4158646A
Cited
US4035533A
Cited
US4086381A
Cited
US4140071A
Cited
US4508771A
Cited
GB2067135A
Cited
US4336286A
Cited
US4456665A
Cited
US4576665A
Cited
USRE31826E
Cited
JPS60109806A
Cited
US4624878A
Cited
US4522857A
Cited
US4673604A
Cited
JPS61119780A
Cited
US4663370A
Cited
US4705706A
Cited
US4875954A
Cited
US4844765A
Cited
JPH0330877A
Cited
WO1991001221A1
Cited
US5109784A
Cited
US5130069A
Cited
US5317070A
Cited
EP0518014A1
Cited
US5370757A
Cited
US5380574A
Cited
US5256224A
Cited
US5283097A
Cited
US5240530A
Cited
US5288349A
Cited
JP3030877U
Cited
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1999-11-26 | 2000-05-27 | 2000-11-26 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2003-11-26 | 2004-05-27 | 2004-11-26 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2007-11-26 | 2008-05-27 | 2008-11-26 | $7700.00 | Window Closed / Lapsed |