Static structures (e.g. – buildings) – Processes – Sealing
Reexamination Certificate
1998-11-13
2001-07-03
Safavi, Michael (Department: 3635)
Static structures (e.g., buildings)
Processes
Sealing
C052S506050, C052S741100
Reexamination Certificate
active
06253526
ABSTRACT:
FIELD OF THE INVENTION
This invention relates to a process for installing carpet having water resistant or impermeable underlays.
BACKGROUND OF THE INVENTION
Water resistant and impermeable carpet underlays provide a way to clean spills on carpet more thoroughly by containing the spill above the padding, thus preventing the spill from wetting the padding and flooring underneath. The resistant or impermeable barrier provides advantages since, if a spill is not removed from under the carpet, the spill will allow the growth of mold, mildew, and bacteria. Such underlays may be treated with antibacterial and antifungal agents. Not only may the padding and wood flooring deteriorate as a result, but such conditions are conducive to the formation of odors and allergens.
Spills on fitted or wall-to-wall carpeting are particularly insidious since detection and prevention of the seepage into the padding following a spill is typically impractical with large or fitted carpets. A spill on broadloom carpeting often puddles on the padding or flooring where it can not be removed by cleaning.
This spill then accelerates the growth of mold, mildew and odors. By allowing spills to be more thoroughly cleaned, a water resistant or impermeable backing reduces the growth of mold and mildews which cause odors.
Murphy, in U.S. Pat. Nos. 5,601,910 and 5,763,040, described processes to treat a carpet underlay to make it substantially impermeable to spills. By careful selection of both the water repellent finish and adhesive, the water impermeable underlay was adhered to the underside of the carpet creating a barrier to spills.
Underlays are usually attached to the underside of the carpet by an adhesive applied to the upper side of the underlay. Alternatively the underlay may be treated with adhesive on both sides to attach it to both the underside of the carpet and the padding. The adhesive prevents movement of the underlay as the carpet is laid, and also prevents any movement due to traffic after the installation is complete. Such application methods have been highly effective, but there are added costs associated with the adhesive, necessary release papers, and installation.
The prior art also describes water impermeable carpeting constructed using impermeable backings such as those based on poly(vinyl chloride) and polyurethane to replace the usual latex backing, and also sheets of plastic, such as polyethylene and poly(ethylene/vinyl acetate), that are laminated to the carpet.
However, such backings are expensive, create manufacturing difficulties, and prevent desirable breathability (air permeability) of the carpet.
It would be advantageous if a simpler method for laying the padding, underlay, and carpet were available which would reduce the costs associated with the adhesive, necessary release papers, and installation. The present invention provides such an improved process for installation of a water resistant or water impermeable underlay with padding and carpet.
SUMMARY OF THE INVENTION
The present invention comprises a process for installing a carpet underlay resistant to water comprising
a) placing a padding over a flooring, and optionally securing said padding into the flooring,
b) placing an underlay over said padding, and
c) mechanically securing the underlay through said padding into the flooring with fasteners,
wherein said underlay comprises a water resistant fabric or film, whereby said resistance is measured by pouring 20 ml of water on a test sample of carpet at a location over an underlay fastener from a height of 6 cm and results in no wet spot after 30 minutes, or a wet spot having a diameter of a maximum of 2.54 cm on a paper towel placed between the underlay and the padding directly beneath the location on which said water has been poured.
The present invention further comprises a process for installing a carpet underlay impermeable to water comprising
a) placing a padding over a flooring, and optionally securing said padding into the flooring,
b) placing an underlay over said padding, and
c) mechanically securing the underlay through said padding into the flooring with fasteners,
wherein said underlay comprises a water impermeable fabric or film, whereby said impermeability is measured by pouring 20 ml of water on a test sample of underlay at a location over an underlay fastener from a height of 6 cm and results in no wet spot after 10 minutes, or a wet spot having a diameter of a maximum of 2.54 cm on a paper towel placed between the underlay and the padding directly beneath the location on which said water has been poured.
The present invention further comprises the product of the above processes.
DETAILED DESCRIPTION OF THE INVENTION
The process of the present invention comprises stapling, nailing, or otherwise mechanically attaching an underlay through padding to the flooring using fasteners. Hereinafter, the terms “secure”, “secured”, “securing”, “securement” are used to describe aspects of the attachment of the underlay by means of staples, nails, or other mechanical means of attachment. Specifically excluded is the use of adhesive or adhesive tape as a means of attachment of the underlay. By the term “flooring” is meant any surface to be carpeted.
In the present invention carpet padding is laid conventionally. The underlay, without adhesive, is secured through the padding to the flooring, and the carpet is laid conventionally on the secured underlay. The present invention simplifies the installation of water resistant and water impermeable underlays by securing the underlay fabric to the padding and underneath flooring without compromising the integrity of the water resistant or water impermeable barrier, even though securing, as used in the context of this invention, punches holes in the underlay.
The terms “water resistant” and “water resistance”, as applied hereinafter to underlays, mean that the underlay, under the conditions of Test Method 3 described hereinafter, prevents the penetration of water through the underlay into the underlying padding. It is understood that water resistant means resistant to water and aqueous solutions and suspensions, including coffee, wine, soda, fruit juices, urine, and the like. More specifically, the terms water resistant and water resistance mean that, under the conditions of Test Method 3, the wet spot diameter on the paper towel after 30 minutes is one inch (2.54 cm) or less. Test Method 3 comprises testing carpet and secured underlay and padding.
The terms “water impermeable” and “water impermeability” as used herein applied to underlays mean that the underlay, under the conditions of Test Method 4 described hereinafter, prevents the penetration of water through the underlay into the underlying padding. It is understood that water impermeable means impermeable to water and aqueous solutions and suspensions, including coffee, wine, soda, fruit juices, urine, and the like. More specifically, the terms water impermeable and water impermeability mean that, under the conditions of Test Method 4, the wet spot diameter on the paper towel after 10 minutes is one inch (2.54 cm) or less. Test Method 4 comprises testing secured underlay and padding without carpet. Test Method 4 is more stringent than Test Method 3 since, in Test Method 3, the tendency for water to penetrate is reduced as it is at least partially absorbed by the carpet.
The process of the present invention provides several advantages. It (i) allows fabrics without adhesive to be used as water resistant or water impermeable underlays, (ii) simplifies the installation of the underlay, (iii) preserves the integrity of the water resistant or water impermeable barrier at seams between adjacent sheets of the underlay, (iv) eliminates the need for release sheets on the adhesive coated side or sides of the underlay, (v) eliminates the nuisance of the adhesive coated fabric sticking to itself, (vi) holds the underlay more firmly to the padding and underneath flooring, and (vii) allows the flexibility to install the underlay just in desired areas.
Carpeting requires a solid foundation
Cathey Anne Dowdell
Dittman Misty Dawn
Materniak Joyce Monson
Murphy Peter Michael
E.I. Du Pont de Nemours and Company
Safavi Michael
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