Static structures (e.g. – buildings) – Processes – Adhering preformed sheet-form member
Reexamination Certificate
2002-07-18
2003-07-15
Crispino, Richard (Department: 1734)
Static structures (e.g., buildings)
Processes
Adhering preformed sheet-form member
C052S177000, C156S071000
Reexamination Certificate
active
06591578
ABSTRACT:
FIELD OF INVENTION
The present invention relates generally to carpets, and, more specifically, to an improved method of installing wall-to-wall carpet.
BACKGROUND OF THE INVENTION
Wall-to-wall carpet has been a popular floor covering for many years. However, the method of installing wall-to-wall carpet has not changed much over the years. Typically, wall-to-wall carpet is installed by nailing tack strips around the periphery of a room in which the carpet is to be installed. If the carpet does not include an integral cushion or pad, a separate cushioning pad may then be placed on the floor between the tack strips. The carpet is cut to a size slightly larger than the actual size of the room. One edge of the carpet is then secured to the tack strips adjacent that edge and trimmed with a knife to exact size, usually to fit under a baseboard. The carpet is then stretched so that it is under tension and the opposite edge of the carpet is secured to the tack strip adjacent that opposite wall. A similar procedure is followed to secure the lateral edges of the carpet. The carpet is then trimmed to the exact dimensions of the room so that the carpet extends from wall-to-wall.
It is necessary to stretch wall-to-wall carpet when it is installed so that the carpet will not wrinkle, puckering, buckle or otherwise assume a non-planar shape due to dimensional changes of the carpet. Since the carpet is bounded on opposite ends by fixed walls, any significant increase in the length of the carpet due to increases in humidity or moisture conditions will produce wrinkling, puckering or buckling of the carpet. Therefore, carpets are usually stretched or “kicked in” during installation to avoid problems associated with humidity or moisture induced dimensional changes.
Stretching of wall-to-wall carpet does not always solve the problem of wrinkling or buckling of the carpet over a period of time. Frequently, wall-to-wall carpets must be re-stretched due to elongation of the carpet under tension.
Due to the disadvantages of the tack strip method of installing wall-to-wall carpet, alternative methods of installation have been developed. One such alternative method is to glue the carpet to the floor with an adhesive. However, when the carpet is removed, particularly carpet that includes an integral, cushioning pad, a significant residue is left on the floor requiring relatively large amounts of labor to prepare the floor for a subsequent installation of another floor covering. Furthermore, like tack-strip installed carpet, glued-down carpet cannot easily be removed for cleaning.
Another alternative method of installation of wall-to-wall carpet is the hooks and loops, such as Velcro, method of installation. Instead of installing tack strips around the periphery of a room, strips of either hooks or loops are glued to the floor. Corresponding mating strips of hooks or loops are then glued or otherwise attached to the edge of the carpet so that when the strip on the floor is contacted with the strip on the carpet, the hooks and loops will form a temporary mechanical bond.
The traditional methods of installing wall-to-wall carpet described above have several disadvantages. First, they are labor intensive and time consuming processes, and, therefore, are relatively expensive to perform. Second, installation is relatively permanent; therefore, the carpet cannot be easily removed for cleaning. Third, installation requires special tools. Fourth, the installation is not conducive to working with combinations of carpets, colors and the like, for design development and color contrast visual effects. Last, the take-up and removal of traditionally installed carpet is a relatively significant portion of the cost of replacing carpet. Thus, a need exists for an improved method of installing wall-to-wall carpet that overcomes the disadvantages of the prior art.
SUMMARY OF THE INVENTION
The present invention satisfies the above-described needs by providing an improved method of installing wall-to-wall carpet. The method comprises installing a wall-to-wall carpet on a substrate bounded at least partially by opposed walls by securing to the substrate an intermediate member having a top surface comprising a skid resistant plastic film, applying to the top surface of the intermediate member the bottom surface of the carpet comprising a skid resistant plastic film, such that said carpet resists dimensional changes due to changes in moisture or humidity without the use of tack strips securing the periphery of said carpet to said substrate, said intermediate member and said carpet being substantially free of adhesive for retaining said carpet and said intermediate member together; and cutting the carpet to conform to a desired shape at least partially bounded on two sides by the opposed walls.
In another embodiment of the present invention, the method comprises installing a wall-to-wall carpet on a substrate bounded at least partially by opposed walls, the carpet having a bottom surface, by applying to the substrate an intermediate member comprising a layer of polyurethane foam attached on one side to a layer of nonwoven textile material and on the other side to a skid resistant plastic film, the nonwoven layer being disposed adjacent to the substrate; applying to the plastic film surface of the intermediate member the bottom surface of the carpet, the bottom surface of the carpet having a skid resistant plastic film attached thereto such that said carpet resists dimensional changes due to changes in moisture or humidity without the use of tack strips securing the periphery of said carpet to said substrate, said intermediate member and said carpet being substantially free of adhesive for retaining said carpet and said intermediate member together; and cutting the carpet to conform to a desired shape at least partially bounded on two sides by the opposed walls.
In another embodiment of the present invention, the method of installing a wall-to-wall carpet on a substrate bounded at least partially by opposed walls, the carpet having a bottom surface, comprises applying a skid-resistant coating to the substrate, applying to the coated substrate the bottom surface of the carpet that includes a skid resistant plastic film such that said carpet resists dimensional changes due to changes in moisture or humidity without the use of tack strips securing the periphery of said carpet to said substrate, said substrate and said carpet being substantially free of adhesive for retaining said carpet and said substrate together and cutting the carpet to conform to a desired shape at least partially bounded on two sides by the opposed walls.
In a further embodiment of the present invention, the method of installing a wall-to-wall carpet on a substrate bounded at least partially by opposed walls, said carpet having a bottom surface, comprises applying a skid-resistant coating to the substrate, applying to the coated substrate an intermediate member having a top surface comprising a skid resistant plastic film, applying to the top surface of the intermediate member the bottom surface of the carpet, the bottom surface of the carpet comprising a skid resistant plastic film such that said carpet resists dimensional changes due to changes in moisture or humidity without the use of tack strips securing the periphery of said carpet to said substrate, said intermediate member and said carpet being substantially free of adhesive for retaining said carpet and said intermediate member together; and cutting the carpet to conform to a desired shape at least partially bounded on two sides by the opposed walls.
In yet another embodiment of the present invention, the method comprises installing a wall-to-wall carpet on a substrate bounded at least partially by opposed walls by securing to the substrate an intermediate member having a top surface comprising a skid resistant plastic film, applying to the top surface of the intermediate member the bottom surface of the carpet comprising a skid resistant coating, such that the carpet resists dimensional changes due to
Chan Sing P
Crispino Richard
Kilpatrick & Stockton LLP
LandOfFree
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