Patent ID: 6406574
Filing Date: 2002-06-18
Classification: B32B,D06N,Y10T

Abstract:
A method of assembling a floor covering comprising the steps of:providing a carpet layer having textile fibers defining an upper surface and having an opposing carpet layer back surface; forming a vinyl layer on the carpet layer back surface; and adhering a pre-formed polymeric backing layer to the vinyl layer, the pre-formed polymeric backing layer having a front backing surface for adhering to the vinyl layer and an opposing rear backing surface wherein the carpet layer is provided as a continuous sheet and the steps of forming a vinyl layer and adhering a pre-formed polymeric backing layer are performed on the carpet layer in a continuous manner in a single carpet finishing line, and wherein the step of forming a vinyl layer includes the following sequence of steps depositing a first portion of uncured vinyl material on the carpet layer back surface; spreading the first portion of uncured vinyl material across the carpet layer back surface to form the vinyl layer; and passing the carpet layer and the vinyl layer between a thickness control roller and a base surface in a predetermined direction, the control roller having an outer surface, a portion of which engages the vinyl layer, the control roller being rotated at a predetermined rate in a direction such that the portion of the control roller surface engaging the vinyl material moves in a direction opposite to the predetermined direction of motion of the carpet layer thereby establishing a substantially uniform vinyl layer thickness.