US 12,320,064 B2
Carpet tile with wet laid dual layer nonwoven mat
Richard T Hausman, Waterville, OH (US); Souvik Nandi, Highlands Ranch, CO (US); Philip Christopher Sharpe, Weddington, NC (US); and Steven Westbrook, Mount Juliet, TN (US)
Assigned to Johns Manville, Denver, CO (US)
Filed by JOHNS MANVILLE, Denver, CO (US)
Filed on Jun. 5, 2019, as Appl. No. 16/431,831.
Prior Publication US 2020/0385922 A1, Dec. 10, 2020
Int. Cl. D06N 7/00 (2006.01)
CPC D06N 7/0071 (2013.01) [D06N 7/0036 (2013.01); B32B 2471/02 (2013.01); D06N 2201/082 (2013.01); D06N 2209/1628 (2013.01); Y10T 428/23979 (2015.04)] 17 Claims
OG exemplary drawing
 
1. A carpet tile, comprising:
a pile fabric layer;
a primary backing coupled with the pile fabric layer;
a secondary backing coupled with the primary backing; and
a dual-layer wet-laid nonwoven mat, the dual-layer wet-laid nonwoven mat comprising:
a first layer comprising a plurality of glass fibers and a plurality of synthetic fibers;
a second layer comprising a plurality of synthetic fibers and a plurality of glass fibers, and
a single binder that bonds the plurality of glass fibers and plurality of synthetic fibers of the first layer together, bonds the plurality of synthetic fibers and plurality of glass fibers of the second layer together, and bonds the first layer and the second layer together, wherein:
a percentage by weight of the glass fibers in the first layer is between 70 and 99 percent and a percentage by weight of the synthetic fibers in the first layer is between 1 and 30 percent;
a percentage by weight of the synthetic fibers in the second layer is between 80 and 99 percent;
the plurality of glass fibers comprise coarse glass fibers having an average fiber diameter between about 8 and 25 um;
the plurality of glass fibers comprise glass microfibers having an average fiber diameter between about 0.5 and 6 um;
the plurality of synthetic fibers comprise a first type of synthetic fibers having an average denier of between 0.3 and 1 denier and a second type of synthetic fibers having an average denier of between 1.5 and 8 denier; and
a porosity of the first layer is greater than a porosity of the second layer.