US 12,420,539 B2
Single pass carpet-production method and carpets prepared using same
Michael E. Bell, Lexington, VA (US)
Assigned to Aladdin Manufacturing Corporation, Calhoun, GA (US)
Appl. No. 17/758,440
Filed by Aladdin Manufacturing Corporation, Calhoun, GA (US)
PCT Filed Jan. 6, 2021, PCT No. PCT/US2021/012255
§ 371(c)(1), (2) Date Jul. 6, 2022,
PCT Pub. No. WO2021/141947, PCT Pub. Date Jul. 15, 2021.
Claims priority of provisional application 62/957,947, filed on Jan. 7, 2020.
Claims priority of application No. 20154810 (EP), filed on Jan. 31, 2020.
Prior Publication US 2023/0024402 A1, Jan. 26, 2023
Int. Cl. B32B 37/24 (2006.01); A47G 27/02 (2006.01); B32B 5/02 (2006.01); B32B 5/26 (2006.01); B32B 27/12 (2006.01); B32B 27/20 (2006.01); B32B 27/32 (2006.01); B32B 37/02 (2006.01); B32B 37/15 (2006.01); D06N 3/00 (2006.01); D06N 3/04 (2006.01)
CPC B32B 37/24 (2013.01) [A47G 27/02 (2013.01); B32B 5/022 (2013.01); B32B 5/028 (2013.01); B32B 5/265 (2021.05); B32B 27/12 (2013.01); B32B 27/20 (2013.01); B32B 27/32 (2013.01); B32B 37/02 (2013.01); B32B 37/153 (2013.01); D06N 3/0056 (2013.01); D06N 3/045 (2013.01); B32B 2037/243 (2013.01); B32B 2250/03 (2013.01); B32B 2255/02 (2013.01); B32B 2255/26 (2013.01); B32B 2260/021 (2013.01); B32B 2260/046 (2013.01); B32B 2262/101 (2013.01); B32B 2305/073 (2013.01); B32B 2305/08 (2013.01); B32B 2305/30 (2013.01); B32B 2305/38 (2013.01); B32B 2305/74 (2013.01); B32B 2307/718 (2013.01); B32B 2315/085 (2013.01); B32B 2323/04 (2013.01); B32B 2323/10 (2013.01); B32B 2471/02 (2013.01); D10B 2503/042 (2013.01)] 20 Claims
OG exemplary drawing
 
1. A method of manufacturing a carpet or carpet tile, the method comprising:
providing a facecloth, wherein the facecloth comprises a primary backing having a plurality of face yarns extending through the primary backing;
forming a multi-layer construction comprising the facecloth and a backing construction secured on a bottom side of the facecloth by:
applying a polyolefinic coating onto the bottom side of the facecloth;
pressing a first side of a reinforcing scrim layer onto the polyolefinic coating applied to the bottom side of the facecloth; and
extruding a polyolefin-based resin onto a second side of the reinforcing scrim layer, thereby forming an extruded polyolefin sheet having a top surface which is bonded to the reinforcing scrim layer; and
wherein the polyolefinic coating has a viscosity less than 2000 mPa·s at 400° F., and the reinforcing scrim layer comprises a composite material of a first layer of a polymer-based fiber material and a second layer of a glass fiber material.