Abstract:
This invention relates to methods for manufacturing plates bonded to resilient layers, wherein the plate is made of a polypropylene and the resilient layer is made of a polyethylene. Ultrasonic welding used to bond the resilient layer to the plate. In some embodiments, a thin film is applied to a layer of the resilient layer before ultrasonic welding. While the film layer may be located adjacent the plate when welding, the film layer may also be advantageously located on the opposite of the resilient layer from the plate when welding. The film may also be applied to both sides of the resilient layer.
Abstract:
Attachment devices are described for attaching and locating overlapped anchor sheets while allowing for some relative movement as to expansion and contraction. Generally, the devices are a male/female connection on corresponding sheets and expansion openings or apertures surrounding either the male or female part to provide for areas of flexibility to provide for possible movement of either the male or female part.
Abstract:
A system and method for manufacturing a substrate having a bed of hooks located therein, in particular a system or manufacturing a hook plate having hooks with enlarged shaped heads. The system can include the use of a heated generally flat coining plate, a resilient layer placed under the hook plate, and a forming sheet placed between the coining plate and the tops of stems to be coined.
Abstract:
A carpet tile having a first layer of a non-woven primary backing having pile elements tufted through the backing to form loops on an underside of the backing is described. The tile includes a second layer of a secondary backing and having loops provided substantially across the underside of the secondary backing for attachment to hooks of a hook and loop attachment system. The tile further includes a hot melt binder which fastens the first and second layers to each other. The carpet tile is free of a stabilizing layer.
Abstract:
An improved anchor sheet is described. The anchor sheet can be injection molded from polypropylene and can have a thickness of between 0.031 inches and 0.75. Such an anchor sheet can be molded with hooks and can have an attached resilient layer. Stems integral with the anchor sheet are used to form the hooks, and may be lmm high and 0.55 mm in diameter. The density of stems may be approximately 230 per square inch, or approximately 128,000 stems on a plate. An anchor sheet made in this way makes an excellent field of hooks when installed onto a supporting surface such as a floor. This field of hooks can take an overlying decorative covering such as pieces of loop backed carpet. When a resilient layer is attached, for example by ultrasonic welding, to the underside of the anchor sheet, between the anchor sheet and the floor, the anchor sheet can have the right degree of 'give', so that a user can experience some cushioning effect from the resilient layer below the anchor sheet, but with some level of rigidity so that the load of walking is transmitted across a larger surface and does not 'dig' into the resilient layer.
Abstract:
A floor covering containing a decorative pattern is described. The floor covering has a field of hooks substantially covering a floor to receive decorative overlaid pieces. The covering further has a carrier sheet comprising a top side substantially covered in hooks, such hooks being one half of a hook and loop attachment system, and a bottom side substantially covered in loops, such loops being a second half of a hook and loop attachment system. The carrier sheet is detachably attached by its loops to the field of hooks. The covering further has a first set of decorative pieces having a bottom side substantially covered in loops, such being one half of a hook and loop attachment system. The set of decorative pieces are detachably attached to the upper surface of the carrier sheet and comprise a visually distinct design sheet which substantially entirely fills the upper surface of the carrier sheet. Furthermore, the covering has a second set of decorative pieces having a bottom side substantially covered in loops, such loops being one half of a hook and loop attachment system, which are detachably attached to the field of hooks to fill the space around the set of decorative pieces.