| US 7,374,808 B2 | ||
| Patterned bonded carpet and method | ||
| N. David Sellman, Jr., LaGrange, Ga. (US); and Kyle T. Veatch, LaGrange, Ga. (US) | ||
| Assigned to Milliken & Company, Spartanburg, S.C. (US) | ||
| Filed on Jul. 16, 2001, as Appl. No. 9/906,282. | ||
| Claims priority of provisional application 60/219979, filed on Jul. 21, 2000. | ||
| Prior Publication US 2002/0046433 A1, Apr. 25, 2002 | ||
| Int. Cl. B32B 33/00 (2006.01); B32B 37/00 (2006.01); D06B 1/02 (2006.01); D06B 11/00 (2006.01) | ||
| U.S. Cl. 428—94 [428/95; 428/92; 428/196; 8/150; 8/929; 8/499; 347/105; 347/106; 156/72; 156/250; 156/269; 156/270] | 18 Claims |
| 1. A method of producing bonded flooring, comprising the steps of:
bonding a carpet substrate with a carpet yarn using a water based latex adhesive, wherein the carpet yarn is at least one
of all white, light colored, pre-dyed with a single color, pre-dyed with multiple colors, naturally colored, and chemically
treated to absorb dyes differently in arbitrary areas of the carpet to form a cut pile, fusion bonded carpet having a pile
height of about 0.190-0.220 inches and a yarn density of about 9-15 folds per inch and 10-20 ends per inch,
jet dyeing at least one of a background color, design, pattern, or border, on the fusion bonded carpet by applying liquid
dye at a DPI greater than the DPI of the bonded carpet such that the applied dye migrates from terminal ends of the carpet
yarn to the water based latex,
and cutting or forming the jet dyed fusion bonded carpet into a completed item or product selected from the group consisting
of carpet tiles, area rugs, runners, carpets, rugs, broadloom, and wall to wall carpet.
|