Patent Description:
<CIT>, <CIT>, <CIT> and <CIT> disclose carpets.

Further, carpet on top of a wet subfloor, particularly for an extended period of time, may be subject to a number of issues. One is that the carpet may develop mold or mildew. The presence of mildew in an area can cause respiratory issues for anyone who inhales mildew spores. Mold can cause even more severe health issues, such as long-term respiratory and cardiovascular issues, as well as causing structural damage. Mold and mildew may be more likely to develop in a carpeted area, compared to the same area without carpet, as moisture may become trapped under the carpet. Further, the presence of moisture may weaken adhesive that binds layers of carpet together, decreasing its usable life. Carpet in which the layers may move relative to one another can also pose a slip-and-fall danger. Moisture-related problems are particularly acute when carpet is on top of a concrete subfloor.

Accordingly, a need exists for durable carpet tiles having desirable flatness characteristics and ability to prevent mold and mildew buildup, and other damage, due to moisture.

Various embodiments are directed to a carpet tile comprising a tufted primary backing defining a top wear surface comprising a plurality of tufted fibers. The opposite, backside of the primary backing may be coated with a pre-coat layer to lock the carpet tufts into the primary backing. The coated primary backing has an extruded polymer secondary backing secured thereto, and the extruded polymer secondary backing has a polyester cushion bound thereto to define the bottom surface of the carpet tile.

The invention according to claim <NUM> is directed to a carpet tile comprising a facecloth comprising a primary backing and a plurality of face yarns extending through the primary backing, wherein the facecloth defines an upper surface of the carpet tile; an extruded polymer secondary backing layer bonded to the facecloth; and a polyester cushion bonded to the bottom surface of the extruded polymer secondary backing, said polyester cushion comprising a reinforcing scrim layer embedded within a polyester layer; and wherein the polyester cushion defines at least a portion of a bottom surface of the carpet tile.

In certain embodiments, the polyester cushion comprises a weight ratio of <NUM> to <NUM> oz per square yard, of which <NUM> to <NUM> oz per square yard is reinforcing scrim layer. In certain embodiments, the polyester cushion comprises a weight ratio of polyester to reinforcing scrim layer of <NUM>:<NUM> to <NUM>:<NUM>.

In certain embodiments, the reinforcing scrim layer comprises a plurality of fibers and wherein the plurality of fibers comprise at least one of: glass fibers or polymer fibers. In certain embodiments, the plurality of fibers comprise polymer fibers comprises sheathed polyester core fibers. In certain embodiments, the reinforcing scrim layer comprises a plurality of nonwoven fibers. In certain embodiments, the reinforcing scrim layer comprises a nonwoven fiber mat. In certain embodiments, the nonwoven fiber mat comprises an air-laid grid. In certain embodiments, the reinforcing scrim layer comprises a woven fiber mat. In certain embodiments, the reinforcing scrim layer comprises a plurality of polymer fibers and a plurality of glass fibers.

In certain embodiments, the extruded polymer secondary backing comprises a polyolefin. In certain embodiments, the extruded polymer secondary backing may comprise, for example, in an amount between about <NUM>-<NUM> wt% of the weight of the extruded polymer secondary backing. The extruded polymer secondary backing may additionally comprise an inert filler material in an amount between about <NUM>-<NUM> wt% of the weight of the extruded polymer secondary backing.

In certain embodiments, the weight of the carpet tile is between about <NUM>-<NUM> ounces per square yard. In certain embodiments, the weight of the carpet tile is between about <NUM>-<NUM> ounces per square yard.

In certain embodiments, the facecloth may additionally comprise a primary backing pre-coat layer between the primary backing layer and the extruded polymer secondary backing layer.

In certain embodiments, the extruded polymer secondary backing comprises a weight ratio of between about <NUM>-<NUM> ounces per square yard.

The invention according to claim <NUM> is a method of manufacturing a carpet tile, the method comprising providing a facecloth, wherein the facecloth comprises a primary backing having a plurality of face yarns extending through a facecloth, wherein in some embodiments a pre-coat layer has been applied to a first side of the facecloth; forming a multi-layer construction comprising the facecloth and a backing construction secured on the first side of the facecloth by: extruding a polymer secondary backing onto the first side of the facecloth; pressing a polyester cushion against a bottom surface of the extruded polymer secondary backing to bond the polyester cushion to the bottom surface of the extruded polymer secondary backing such that the polyester cushion defines at least a portion of a bottom surface of the carpet tile; and, in certain embodiments, chilling the multi-layer construction, or cutting the carpet web into a plurality of carpet tiles. In certain embodiments, bonding the polyester cushion to the extruded polymer secondary backing comprises compressing the multi-layer construction between nip rollers.

In certain embodiments, the polyester cushion comprises <NUM> to <NUM> oz of polyester per square yard, of which <NUM> to <NUM> oz of reinforcing scrim layer per square yard. In certain embodiments, the polyester cushion comprises a weight ratio of polyester to reinforcing scrim layer of <NUM>:<NUM> to <NUM>:<NUM>.

In certain embodiments, extruding the polymer secondary backing comprises extruding a polyolefin-based resin comprising between about <NUM>-<NUM> wt% polyolefin and between about <NUM>-<NUM> wt% of a filler material, measured as portions of the weight of the resin.

In certain embodiments, the reinforcing scrim layer comprises a nonwoven fiber mat. In certain embodiments, the nonwoven fiber mat comprises an air-laid grid. In other embodiments, the reinforcing scrim layer comprises a woven fiber mat. In certain embodiments, the reinforcing scrim layer comprises at least one of: fiberglass fibers or polymer fibers.

In certain embodiments, said steps for extruding a polymer secondary backing onto the first side of the facecloth and pressing a polyester cushion against the extruded polymer secondary backing collectively form a backing construction having a weight between about <NUM>-<NUM> ounces per square yard. In certain embodiments, providing a facecloth comprises providing a primary backing web having a weight between about <NUM>-<NUM> ounces per square yard, or <NUM>-<NUM> ounces per square yard when precoated; and the multi-layer construction has a weight between about <NUM>-<NUM> ounces per square yard.

In certain embodiments, a pre-coat layer has been applied to a first side of the facecloth.

The present disclosure more fully describes various embodiments with reference to the accompanying drawings. It should be understood that some, but not all embodiments are shown and described herein. Indeed, the embodiments may take many different forms, and accordingly this disclosure should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements.

Various embodiments are directed to a dimensionally stable carpet tile that is resistant to both doming and curling, as well as to mold and mildew buildup. The carpet tile is a multi-layer carpet tile comprising a facecloth (comprising a primary backing, face yarn, and optionally a pre-coat layer), bonded to a backing construction comprising an extruded polymer secondary backing layer and a polyester cushion bonded to the extruded polymer secondary backing layer to define, at least in part, the bottom surface of the carpet tile. The polyester cushion comprises a reinforcing scrim layer, usually a fibrous reinforcing scrim layer (e.g., woven or nonwoven) embedded within a polyester layer (which may be woven or nonwoven). The reinforcing scrim layer may also be an air-laid scrim. In certain embodiments, the polyester cushion comprises a weight ratio of <NUM> to <NUM> oz per square yard. In certain embodiments, the reinforcing scrim layer has a weight of <NUM> to <NUM> oz per square yard. The carpet tile product remains resistant to deformation (dimensional deformation, curling, or doming) due at least in part to the presence of the polyester cushion on the bottom surface of the carpet tile. The product is resistant to mold and mildew buildup, due to its ability to wick moisture from the subfloor to the seams, where it may evaporate into the air.

Referring to the figures, in which like numerals refer to like elements through the several figures, <FIG> is a cross sectional view (not to scale) of a carpet tile <NUM> in accordance with various embodiments of the present invention. In the illustrated embodiment, the carpet tile <NUM> includes face yarn <NUM>, which may be either tufted or woven into a primary backing <NUM> to form a facecloth <NUM>. The face yarn <NUM> may be made from various materials, both natural and synthetic, such as nylon <NUM>, nylon <NUM>, <NUM>, cotton, wool, nylon, acrylic, polyester, polyamides, polypropylene, and other polyolefins. The face weight of the face yarn <NUM> can be approximately <NUM> ounces per square yard to approximately <NUM> ounces per square yard.

The primary backing <NUM> may be formed from a substrate such as a woven substrate, a tape yarn substrate, and/or other substrate construction that imparts stability to the carpet tile <NUM>. The substrate may be made from a polyester, such as poly(ethylene terephthalate) [PET], poly(trimethylene terephthalate) [PTT], poly(butylene terephthalate) [PBT], poly(ethylene terephthalate-co-isophthalate), poly(ethylene naphthalene dicarboxylate) [PEN], and copolymers thereof, and/or combinations thereof, with PET being preferred. In certain embodiments, the primary backing <NUM> may comprise a low melt polyester material configured to bind the various fibers together upon application of heat to the primary backing. The substrate may also comprise sheathed fibers, which may comprise a polyester core surrounded by a polyamide and/or polyolefin sheath. Typically, the polyester core may be made from PET, PTT, PBT, PEN, poly(ethylene terephthalate-co-isophthalate) and copolymers thereof. The polyamide sheath may be made from polycaprolactam [nylon <NUM>], poly(<NUM>-heptanamide) [nylon <NUM>], polycapryllactam [nylon <NUM>], poly(<NUM>-nonanamide) [nylon <NUM>], poly(tetramethylene adipamide) [nylon <NUM>,<NUM>], poly(hexamethylene adipamide) [nylon <NUM>,<NUM>], poly(methylene-<NUM>,<NUM>'-dicyclohexylene dodecanediamide), poly(<NUM>,<NUM>-cyclohexylenedimethulene suberamide), poly(m-phenylene isophthalamide), and poly(p-phenylene terephthalamide), with polycaprolactam [nylon <NUM>] being the preferred polyamide. In certain embodiments, the primary backing <NUM> may be formed using a woven substrate using any conventional natural or synthetic woven material, such as cotton, jute, rayon, paper, nylon, polypropylene and other polyolefins, polyamides, polyesters, and the.

The face yarn <NUM> may be tufted through the primary backing <NUM> so that the ends of the face yarn <NUM> extend in an outwardly direction from the topside of the primary backing <NUM> to form an upper surface of the carpet tile <NUM>. Typically the face yarn is tufted into the primary backing <NUM> at a weight of approximately <NUM> ounces per square yard to approximately <NUM> ounces per square yard, and more preferably approximately <NUM> ounces per square yard. The tufting may be performed using conventional techniques that are well known in the art. Furthermore, the tufted face yarn <NUM> loops may be left as uncut to form an uncut pile carpet, cut to form a cut pile carpet, or partially cut to form a tip sheared carpet, as is well known in the art.

In certain embodiments, the facecloth <NUM> includes a pre-coat layer <NUM> that is applied to a first side of the facecloth, which is the same as the bottom surface of the primary backing <NUM>. The pre-coat layer <NUM> penetrates the tufted face yarn <NUM> and encapsulates individual ends of the yarn bundles to at least partially bind the tufted face yarn <NUM> to the primary backing <NUM>. This may prevent one end of an individual fiber from being pulled out of the carpet backing during the manufacturing process. The pre-coat layer <NUM> may also act as a tackifier to provide an acceptable binding surface for a subsequent polymer layer. In an exemplary embodiment, the pre-coat layer <NUM> comprises a hot melt adhesive (HMA) that contains a tackifying resin or agent alone or in combination with polyethylene. In various embodiments, the pre-coat layer <NUM> comprises an aqueous-latex based polymer configured to support the face yarn <NUM> within the primary backing <NUM> upon drying. In certain embodiments, the pre-coat layer <NUM> comprises butadiene acrylate based polymers, vinyl acetate ethylene, vinyl acetateethane copolymers, and/or latex based compounds, such as styrene butadiene copolymer latex (SBR latex). The pre-coat layer <NUM> may include one or more other compositions, such as inert filler materials (e.g., fly ash) as discussed in reference to the extruded polymer secondary backing layer <NUM> herein.

The pre-coat layer <NUM> may be applied to a bottom surface of the primary backing <NUM> in the range of approximately <NUM> ounces per square yard to approximately <NUM> ounces per square yard, and more preferably in the range of approximately <NUM> ounces per square yard to approximately <NUM> ounces per square yard.

Disposed on a bottom surface of the facecloth <NUM> is a backing construction comprising an extruded polymer secondary backing layer <NUM> and a polyester cushion <NUM>. The backing construction is arranged such that the extruded polymer secondary backing layer <NUM> is positioned between the polyester cushion <NUM> and the facecloth <NUM>. In such an embodiment, a first (top) side of the extruded polymer secondary backing layer <NUM> is bonded to the pre-coated facecloth <NUM>, and a second (bottom) side of the extruded polymer secondary backing layer <NUM> is bonded to the polyester cushion <NUM>. The extruded polymer secondary backing layer <NUM> is embodied as a resin comprising one or more components collectively configured to give the resulting carpet tile <NUM> a flat overall appearance without substantial doming (a central portion of the carpet tile <NUM> rising relative to the edges such that a top surface of the carpet tile <NUM> is convex) or curling (the edges of the carpet tile <NUM> rising relative to the central portion such that a top surface of the carpet tile <NUM> is concave). The resin of the extruded polymer secondary backing layer <NUM> may comprise a polyolefin, a thermoplastic polymer, a mixture of two or more polyolefins, or a mixture of one or more polyolefins together with one or more other polymers. For example, the resin may comprise polyvinyl chloride, polyethylene, and/or polypropylene. As specific examples, a polyolefin polymer is embodied as <NUM>-propene, ethylene copolymer or ethylenepropylene copolymer. In certain embodiments, the resin of the extruded polymer secondary backing layer <NUM> comprises the polymer mixture in an amount between about <NUM>-<NUM> wt% of the resin of the extruded polymer secondary backing layer <NUM> (and of the extruded polymer secondary backing layer <NUM> itself). In an embodiment, the carpet tile comprises only one extruded polymer secondary backing layer.

The resin extruded polymer secondary backing layer <NUM> may additionally comprise one or more additives, such as an inert filler material, a colorant, an antioxidant, a tackifier, a viscosity modifier, a flame retardant, and/or the like.

The inert filler material may constitute the majority of the resin of the extruded polymer secondary backing layer <NUM> (by weight), and may function as a low cost material that adds weight to the extruded polymer secondary backing layer <NUM> to aid in forming an at least substantially flat carpet tile <NUM>. For example, the inert filler material may constitute between about <NUM>-<NUM> wt% of the resin and/or the extruded polymer secondary backing layer <NUM>.

The inert filler material may be made from carbonates such as calcium carbonate (CaCO<NUM>), cesium carbonate (CsCO<NUM>), strontium carbonate (SrCO<NUM>), and magnesium carbonate (MgCO<NUM>); sulfates such as barium sulfate (BaSO<NUM>); oxides such as iron oxide (Fe<NUM>O<NUM> or Fe<NUM>O<NUM>), aluminum oxide (Al<NUM>O<NUM>), tungsten oxide (WO<NUM>), titanium oxide (TiO<NUM>), silicon oxide (SiO<NUM>); silicates, such as clay; metal salts; fly ash and the like.

Additionally, the inert filler material may be made from post-consumer products, such as post-consumer glass, post-consumer carpets and/or other post-consumer recycled materials. In cases where the inert filler is made from post-consumer glass, the post-consumer glass is ground into a fine glass powder before it is added as filler. The glass cullet may be made from automotive and architectural glass, also known as plate glass, flint glass, E glass, borosilicate glass, brown glass (bottle glass), green glass (bottle glass), or coal fly ash, or a combination thereof. In the case where post-consumer carpet is used as the inert filler material, the post-consumer carpet maybe ground into a fine cullet and added to the hot melt adhesive. In addition to the post-consumer carpet, remnants and trimmings of carpet (e.g., comprising trim waste from cutting carpet tiles from rolls of carpet, sometimes referred to as window waste), fine waste fibers that are a result of the shearing process, and the like, that are produced as a by-product during the manufacturing process may also be used to form the inert filler material.

The filled or unfilled polymer may also contain a colorant, such as carbon black or another colorant(s) to provide color and increase the opaqueness of the extruded polymer secondary backing layer <NUM>. Typically, the colorant may be present in an amount less than or equal to approximately <NUM> wt% the filled or unfilled resin and extruded polymer secondary backing layer <NUM>. For example, the colorant may be present in an amount between about <NUM>-<NUM> wt% of the extruded polymer secondary backing layer <NUM>. As a specific example, the colorant may be present in an amount of approximately <NUM> wt% of the resin and the extruded polymer secondary backing layer <NUM>.

Moreover, to reduce the possibility of thermo-oxidation degradation, the polymer may also contain one or more antioxidants. Some suitable antioxidants include, but are not limited to amines, <NUM>,<NUM>'-methylene bis-(<NUM>-methyl-<NUM>-tert-butylphenol), <NUM>,<NUM>,<NUM>-tri-tert-butylphenol, <NUM>,<NUM>-di-tert-butyl-<NUM>-methylphenol, <NUM>,<NUM>'-thio-bis-(<NUM>-tert-butyl-m-cresol), butylated hydroxy anisole, butylated hydroxy toluene, bis(hydrogenated tallow alkyl),oxide; tris(<NUM>,<NUM>-ditert-butylphenyl)phosphite and <NUM>,<NUM>,<NUM> triazine-<NUM>,<NUM>,<NUM>(<NUM>, <NUM>, SH)-trione, <NUM>,<NUM>,<NUM>,tris-((<NUM>,<NUM>-(<NUM>-dimethylethyl))-<NUM>-hydroxyphenyl)methyl. Typically, the antioxidant may be present in the filled or unfilled extruded polymer secondary backing layer <NUM> in an amount less than or equal to approximately <NUM> wt % of the resin and/or the extruded polymer secondary backing layer <NUM>, such as between about <NUM>-<NUM> wt% of the resin and/or the extruded polymer secondary backing layer <NUM>.

Moreover, the extruded polymer secondary backing layer <NUM> may additionally include one or more tackifiers to aid in forming a strong mechanical bond with the pre-coat layer <NUM> (if present), the primary backing <NUM>, and/or the polyester cushion <NUM> discussed in further detail below.

The resin of the polymer secondary backing layer <NUM> may additionally include one or more viscosity modifiers and/or compatibilizers, such as, for example, olefins of higher or lower molecular weight than the resin discussed herein or ethylene maleic anhydride copolymer, to ensure proper flow and bonding of the resin within filler and polymers when applying onto a facecloth <NUM>. The viscosity modifier may be present in an amount between about <NUM>-<NUM> wt% of the resin and the extruded polymer secondary backing layer <NUM>.

In certain embodiments, the resin of the extruded polymer secondary backing layer <NUM> may additionally comprise one or more flame retardants, such as, but not limited to, aluminum trihydrate (ATH) or magnesium hydroxide (MgOH) for applications where flame-retardancy is desired. One or more flame retardants may be necessary to comply with applicable regulations regarding the installation and/or usage of carpet tiles in certain applications, for example, when such carpet tiles are installed in transportation vehicles (e.g., buses, aircraft, and the like).

Referring again to <FIG>, the carpet tile <NUM> additionally comprises a polyester cushion <NUM> pressed against the extruded polymer layer <NUM> to define, at least in part, the bottom surface of the carpet tile <NUM>. The polyester cushion <NUM> imparts dimensional stability to the finished carpet tile <NUM>. Because the polyester cushion <NUM> is positioned on the bottom surface of the carpet tile <NUM>, the polyester cushion <NUM> provides additional support against curling and/or doming of the carpet tile.

The polyester cushion <NUM> comprises a polyester layer <NUM> with an integrated reinforcing scrim layer <NUM>, as seen in <FIG>. In an alternative embodiment (not pictured), the polyester cushion <NUM> does not comprise a reinforcing scrim layer, and consists solely of a polyester layer <NUM>.

The polyester layer <NUM> may comprise any suitable polyester. Such polyesters include, but are not limited to, PET, PTT, PBT, PEN, poly(ethylene terephthalate-co-isophthalate) and copolymers thereof. In a preferred embodiment, the polyester is PET. The polyester layer <NUM> may be woven or nonwoven. In a preferred embodiment, the polyester layer <NUM> is nonwoven.

The reinforcing scrim layer <NUM> may comprise a fibrous material provided in either a woven or non-woven configuration. When provided on the bottom surface of the carpet tile <NUM>, a polyester cushion <NUM> provides desirable protection against mold and mildew formation when the carpet tile <NUM> is on a wet subfloor. In an embodiment, the reinforcing scrim layer <NUM> is in the middle of the polyester cushion <NUM>, such that approximately half of the polyester layer <NUM> is on one side of the reinforcing scrim layer <NUM>, and approximately half of the polyester layer <NUM> is on the other side of the reinforcing scrim layer <NUM>. In other embodiments, about <NUM>-<NUM>% of the polyester layer <NUM> is on one side of the reinforcing scrim layer <NUM>, and about <NUM>-<NUM>% of the polyester layer <NUM> is on the other side of the reinforcing scrim layer <NUM>. In an embodiment, so little of the polyester layer <NUM> is on the top side of the reinforcing scrim layer <NUM> that the reinforcing scrim layer <NUM> is in contact with the extruded polymer layer <NUM>. In an embodiment, a first side of the reinforcing scrim layer <NUM> is in contact with the extruded polymer layer <NUM>, and a second side of the reinforcing scrim layer <NUM> is in contact with the polyester layer <NUM>. In this embodiment, the polyester layer <NUM> may be in contact with the extruded polymer layer <NUM> due to the openness of the reinforcing scrim layer <NUM>.

The reinforcing scrim layer <NUM> may contain fibrous materials, which themselves may constitute any number of natural or synthetic materials. The fibrous material may additionally and/or alternatively comprise one or more polymer based fibers, such as polyester fibers, polyamide fibers, polyurethane fibers, combinations thereof, and/or the like. For example, the polymer fibers may comprise polypropylene fibers, polyethylene fibers, sheathed polymer fibers (e.g., having a polyethylene core and a nylon or polypropylene sheath), and/or the like. As yet another example, the fibrous material may comprise a composite of polymer-based fibers and other fibers (e.g., glass fibers). Such a composite may comprise layers of non-woven and/or woven layers (e.g., a first layer comprising a polymer-based fiber material and a second layer comprising a glass fiber material).

<FIG> is a schematic diagram of a portion of an example carpet tile manufacturing line that may be utilized to construct a carpet tile <NUM> as discussed herein, and <FIG> is a flow chart of an example method for constructing the carpet tile <NUM> according to certain embodiments. As discussed herein, the carpet tiles <NUM> may be manufactured as a portion of a continuous web and later cut into desired tile shapes and sizes. However, it should be understood that carpet tiles <NUM> may be manufactured according to any of a variety of manufacturing processes, such as a batch process in which each multi-layer carpet tile <NUM> is constructed as a separate component.

As shown in <FIG>, the process begins by providing a facecloth <NUM> having a plurality of face yarns <NUM> extending through a primary backing <NUM> (as indicated at Block <NUM> of <FIG>). The facecloth <NUM> can optionally have a pre-coat layer disposed on a backside of the primary backing <NUM>. As discussed herein, the topside of the facecloth <NUM> ultimately forms the top surface of the completed carpet tile <NUM>. As mentioned, the tufted primary backing <NUM> is provided as a continuous web, which may be threaded along a web travel path defined by a plurality of rollers (e.g., powered rollers and/or idler rollers). In certain embodiments, the facecloth <NUM> may have a width between <NUM>-<NUM> inches, although it should be understood that the facecloth <NUM> may have any width with suitable production equipment, such as up to <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, and <NUM> inches.

As shown in <FIG>, the facecloth <NUM> is advanced along the web travel path in an inverted orientation with the backside of the facecloth <NUM> facing upward, as indicated at Block <NUM> of <FIG>. The facecloth <NUM> is advanced past one or more extruder heads <NUM> configured to extrude a continuous sheet of a resin having an at least substantially uniform thickness onto the backside of the facecloth <NUM> to form the extruded polymer secondary backing layer <NUM>, as indicated at Block <NUM>. In certain embodiments, the extruder head <NUM> may comprise a single, elongated extrusion die tip opening extending across the entire width of the facecloth <NUM> such that the resin is extruded as a continuous sheet from the extruder head <NUM>. Alternatively, the resin may be extruded from a plurality of extruder heads <NUM> positioned across the width of the web travel path. The plurality of extruder heads may be spaced such that the resin flows together to form an at least substantially continuous extruded polymer secondary backing layer <NUM> having an at least substantially uniform thickness across the width of the facecloth <NUM>.

The one or more extruder heads <NUM> may be supplied by one or more extruders (e.g., single screw extruders and/or dual-screw extruders) configured to combine the various components of the resin prior to extrusion to form the extruded polymer secondary backing layer <NUM>. Once combined, the extruders and one or more extruder heads <NUM> provide the at least substantially continuous sheet of resin onto the bottom surface of the facecloth <NUM> at a temperature between about <NUM>-<NUM> degrees Fahrenheit and at a weight of between about <NUM>-<NUM> ounces per square yard. In embodiments in which the facecloth <NUM> comprises a hot melt pre-coat layer <NUM>, the resin may be applied to the facecloth <NUM> while the pre-coat layer <NUM> is sufficiently hot (as may be the case with a hot melt adhesive) so as to retain a tacky characteristic (e.g., while the pre-coat layer material remains above its softening point) to improve the mechanical bond strength between the facecloth <NUM> and the extruded polymer secondary backing layer <NUM>. However, it should be understood that the resin need not be applied to the facecloth <NUM> while a pre-coat layer <NUM> remains hot in embodiments that do not utilize a hot melt adhesive pre-coat layer <NUM> (e.g., embodiments without a pre-coat layer <NUM> and embodiments using an aqueous latex-based pre-coat layer <NUM>).

After extruding the resin of the extruded polymer secondary backing layer <NUM> onto the facecloth <NUM>, the polyester cushion <NUM> is laid onto the exposed bottom surface of the extruded polymer secondary backing layer <NUM> as indicated at Block <NUM> of <FIG>. The extruded polymer secondary backing layer <NUM> remains above the resin softening point when the polyester cushion <NUM> is laid onto the exposed surface of the extruded polymer secondary backing layer <NUM>, and the entire multi-layer web (including the facecloth <NUM>, the extruded polymer secondary backing layer <NUM>, and the polyester cushion <NUM>) is passed through a nip <NUM> comprising two rollers positioned on opposite sides of the web travel path to compress the multi-layer web and to provide strong bonds between adjacent layers of the carpet tile <NUM>. During compression, the extruded polymer secondary backing layer <NUM> is bonded to the facecloth <NUM>, and the polyester cushion <NUM> is bonded to the extruded polymer secondary backing layer <NUM> (as indicated at Block <NUM>). The polyester cushion <NUM> defines at least a portion of the bottom surface of the resulting carpet tile <NUM>.

After the moving multi-layer web passes through the nip <NUM>, the web passes through one or more chilling rollers <NUM> to cool and harden the extruded polymer secondary backing layer <NUM> (shown at Block <NUM>). For example, the one or more chilling rollers <NUM> may be collectively configured to chill the extruded polymer secondary backing layer <NUM> to approximately room temperature (between about <NUM>-<NUM> degrees Fahrenheit).

In a non-pictured embodiment, the nip rollers may also serve as the chilling rollers.

The cooled multi-layer construction may then be passed to a tile cutting mechanism configured to cut the multi-layer web into a plurality of individual carpet tiles or to a take-up roller <NUM> for storage. For example the web may be passed into a die cutter to cut the material web into market-size carpet tiles <NUM> (e.g., <NUM>"x18", <NUM>"x24", or <NUM>"x36"). Alternatively, the material web may be taken onto a large diameter (e.g., <NUM>-foot diameter) drum where it can be taken to an off-line die cutting station for further processing into carpet tiles <NUM>.

An example carpet tile is manufactured according to the methodology discussed herein. The example carpet tile comprises a facecloth <NUM> comprising a primary backing layer <NUM> having a weight of at least approximately <NUM> ounces per square yard, and having face yarns <NUM> tufted therethough at a weight of at least approximately <NUM> ounces per square yard. The tufted primary backing is coated with a pre-coat layer <NUM> having a dry weight of at least approximately <NUM> ounces per square yard.

The facecloth <NUM> is passed under an extruder head <NUM> as a part of a continuous web, where the resin of the extruded polymer secondary backing layer <NUM> is extruded onto a backside of the facecloth <NUM> (such that the resin is extruded onto the exposed surface of the pre-coat layer <NUM>) to form the extruded polymer secondary backing layer <NUM>. In this example, the extruded polymer secondary backing layer <NUM> comprises a polyolefin resin mixture heated to a temperature of <NUM>-<NUM> degrees Fahrenheit (<NUM>-<NUM> degrees Celsius) for extrusion.

The resin is extruded in a continuous sheet onto the facecloth <NUM> to create an at least substantially uniform extruded polymer secondary backing layer <NUM> having an at least substantially uniform thickness.

Before the extruded polymer secondary backing layer <NUM> cools to a temperature below the softening point of the resin, a polyester cushion <NUM> comprising a reinforcing scrim layer embedded within polyester is laid onto the exposed surface of the extruded secondary backing layer <NUM>, and the entire multi-layer web is passed through a nip <NUM> and through one or more chilling rollers <NUM> to press the polyester cushion <NUM> against the extruded polymer secondary backing layer <NUM> and to cool and harden the extruded polymer secondary backing layer <NUM>. The cooled web is then cut into individual carpet tiles <NUM> for evaluation.

Claim 1:
A carpet tile comprising:
a facecloth comprising a primary backing and a plurality of face yarns extending through the primary backing, wherein the facecloth defines an upper surface of the carpet tile;
an extruded polymer secondary backing layer having a top surface bonded to the facecloth and an opposite bottom surface; and
a polyester cushion bonded to the bottom surface of the extruded polymer secondary backing,
said polyester cushion comprising a reinforcing scrim layer embedded within a polyester layer; and
wherein the polyester cushion defines at least a portion of a bottom surface of the carpet tile.