Patent ID: 6162309
Filing Date: 2000-12-19
Classification: A47G,B32B,D06N,Y10T

Abstract:
A method of producing a carpet in tile or roll form using an open mesh fiber reinforced foam layer with foam nodules comprising the steps of:(a) producing a carpet in tile or roll form having a primary backing through which carpet fiber bundles are tufted and a precoat locking the tufts in place to prevent easy extraction of individual fibers, so that a tufted fiber face and relatively smooth opposite back face are provided,(b) bringing the open mesh fiber reinforced foam layer with foam nodules into intimate contact with the relatively smooth back face; and(c) adhering the open mesh fiber reinforced foam layer with foam nodules in contact with the relatively smooth back face to provide a carpet tile or roll that is substantially prevented from curling or doming, or curling or doming is significantly reduced by applying a non-fused adhesive formulation comprising PVC copolymer, plasticizer, filler, silicone surfactant, and fumed silica, to the relatively smooth back face, and then after step (b), fusing the adhesive at a maximum temperature of about 310.degree. F. to prevent the collapse of the foam nodules of the open mesh fiber reinforced foam layer.