Moisture dissipative floor covering layer

Abstract

A carpet or carpet tile structure for mounting onto an underlying flooring surface comprising a backing layer having a top surface that is connected to a face fabric and a bottom surface that defines a plurality of fluid flow paths for dissipating moisture.

1 . A carpet or carpet tile structure, the structure having at least one side edge, comprising: 
 a face fabric having a bottom side; and    a backing layer having a top surface and an opposed bottom surface, wherein the top surface of the backing layer is proximate to at least a portion of the bottom side of the face fabric, wherein at least a portion of the bottom surface of the backing layer defines a plurality of fluid flow paths, and wherein at least one of the plurality of fluid flow paths extends to at least a portion of one side edge of the structure such that, when the structure is applied to an underlying flooring surface, the fluid flow paths of the backing layer dissipate moisture from between the bottom surface of the backing layer and the underlying flooring surface.    
   
   
       2 . The carpet or carpet tile structure of  claim 1 , further comprising a first adhesive layer disposed between the at least a portion of the bottom side of the face fabric and the top surface of the backing layer.  
   
   
       3 . The carpet or carpet tile structure of  claim 1 , wherein the at least one of the plurality of fluid flow paths that extend to the side edge of a first piece of the structure are in fluid communication with the at least one of the plurality of fluid flow paths that extend to the side edge of an adjoining, second piece of the structure when the first and second pieces are positioned onto the underlying flooring surface.  
   
   
       4 . The carpet or carpet tile structure of  claim 1 , wherein the face fabric comprises: 
 a primary backing material having a face side and a back side;    a plurality of fibers attached to the primary backing material and extending from the face side of the primary backing material, a portion of the plurality of fibers being exposed on the back side of the primary backing material; and    a precoat layer disposed on at least a portion of the back side of the primary backing material, wherein a portion of the precoat layer substantially penetrates therein at least a portion of the primary backing material and substantially consolidates at least a portion of the fibers disposed therein the primary backing material,    wherein the top surface of the backing layer underlies at least a portion of the precoat layer.    
   
   
       5 . The carpet or carpet tile structure of  claim 1 , wherein a portion of the bottom surface of the backing layer has a plurality of spaced male protrusion extending therefrom, whereby the plurality of fluid flow paths are defined therebetween the plurality of spaced male protrusions.  
   
   
       6 . The carpet or carpet tile structure of  claim 5 , wherein the plurality of spaced male protrusions comprise a plurality of spaced parallel rows of substantially co-axial spaced male protrusions, wherein each row extends along a row axis.  
   
   
       7 . The carpet or carpet tile structure of  claim 6 , wherein the male protrusions in adjacent parallel rows are staggered in relation to each other.  
   
   
       8 . The carpet or carpet tile structure of  claim 7 , wherein the bottom surface of the backing layer has a longitudinal axis, and wherein the row axis is offset rotationally relative to the longitudinal axis of the bottom surface at an acute angle α.  
   
   
       9 . The carpet or carpet tile structure of  claim 8 , wherein the acute angle α is between about 10° to about 40°.  
   
   
       10 . The carpet or carpet tile structure of  claim 5 , wherein each spaced male protrusion has a distal end having a cross-sectional shape.  
   
   
       11 . The carpet or carpet tile structure of  claim 10 , wherein the cross-sectional shapes of all of the spaced male protrusions are substantially uniform.  
   
   
       12 . The carpet or carpet tile structure of  claim 10 , wherein the spaced male protrusions have at least two different cross-sectional shapes at the distal end.  
   
   
       13 . The carpet or carpet tile structure of  claim 10 , wherein the cross-sectional shape is substantially circular.  
   
   
       14 . The carpet or carpet tile structure of  claim 5 , wherein each spaced male protrusion has a distal end having a cross-sectional area.  
   
   
       15 . The carpet or carpet tile structure of  claim 14 , wherein the cross-sectional areas of the distal ends of all of the spaced male protrusions are substantially the same.  
   
   
       16 . The carpet or carpet tile structure of claims  14 , wherein the spaced male protrusions have at least two different cross-sectional areas.  
   
   
       17 . The carpet or carpet tile structure of  claim 5 , wherein the bottom surface defines a plurality of troughs, each trough having a minimum depth and a minimum width, and wherein each trough forms a portion of one fluid flow path.  
   
   
       18 . The carpet or carpet tile structure of  claim 17 , wherein at least one trough of a first piece of structure is in fluid communication with at least one trough of an adjoining, second piece of structure when the first and second pieces of structure are positioned onto the underlying flooring surface.  
   
   
       19 . The carpet or carpet tile structure of  claim 5 , wherein the plurality of spaced male protrusions are distributed about the bottom surface.  
   
   
       20 . The carpet or carpet tile structure of  claim 19 , wherein the plurality of spaced male protrusions are arranged in a random pattern.  
   
   
       21 . The carpet or carpet tile structure of  claim 5 , wherein a distal end of at least one of the plurality of male protrusions defines a female depression.  
   
   
       22 . The carpet or carpet tile structure of  claim 21 , wherein the distal end of substantially all of the plurality of male protrusions defines a female depression.  
   
   
       23 . The carpet or carpet tile structure of  claim 1 , wherein the backing layer comprises a resilient spacer member, wherein the spacer member spaces the bottom side from the underlying flooring surface to dissipate moisture from beneath the bottom side, the plurality of fluid flow paths being defined therethrough the spacer member.  
   
   
       24 . The carpet or carpet tile structure of  claim 23 , wherein the spacer member comprises a matrix of self-supporting, randomly convoluted polymeric filaments, the matrix having a thickness of from about ⅛ inches to about ¾ inch.  
   
   
       25 . The carpet or carpet tile of  claim 24 , wherein the polymeric filaments have a diameter of from about 0.010 inches to about 0.040 inches.  
   
   
       26 . The carpet or carpet tile structure of  claim 1 , wherein the backing layer comprises a polyethylene or PVC.  
   
   
       27 . The carpet or carpet tile structure of  claim 1 , wherein the backing layer is formed from a thermoplastic material or a thermoset material.  
   
   
       28 . The carpet or carpet tile structure of  claim 1 , wherein the backing layer is substantially moisture impervious.  
   
   
       29 . The carpet or carpet tile structure of  claim 2 , further comprising a reinforcing fabric layer disposed between the first adhesive layer and the top surface of the backing layer.  
   
   
       30 . The carpet or carpet tile structure of  claim 29 , further comprising a second adhesive layer disposed between the reinforcing fabric layer and the top surface of the backing layer.  
   
   
       31 . A backing layer for a floor covering, such as a carpet or a carpet tile, having at least one side edge, comprising: 
 a side edge; and    a bottom surface, wherein at least a portion of the bottom surface defines a plurality of fluid flow paths thereon, and wherein at least one of the plurality of fluid flow paths extends to at least a portion of the side edge of the backing layer such that the backing layer dissipates moisture from between the bottom surface of the backing layer and an underlying flooring surface when the backing layer is applied to the underlying flooring surface.    
   
   
       32 . The backing layer of  claim 31 , wherein at least a portion of the bottom surface has a plurality of spaced male protrusions extending therefrom, whereby the plurality of fluid flow paths are defined therebetween the plurality of spaced male protrusions.  
   
   
       33 . The backing layer of  claim 32 , wherein the bottom surface further defines a plurality of troughs therebetween the spaced male protrusions, and wherein each trough forms a portion of one fluid flow path.  
   
   
       34 . The backing layer of  claim 32 , wherein the bottom surface of the backing layer has a longitudinal axis, wherein the plurality of spaced male protrusions comprises a plurality of spaced parallel rows of substantially co-axial spaced male protrusions, each row extending along a row axis, wherein the male protrusions in adjacent parallel rows are staggered in relation to each other, and wherein the row axis is offset rotationally at an acute angle α relative to the longitudinal axis of the bottom surface.  
   
   
       35 . A method of manufacturing a carpet or carpet tile structure for mounting onto an underlying flooring surface, the structure having at least one side edge, comprising: 
 providing a face fabric having a bottom side, wherein the face fabric comprises yarn attached thereto;    applying a backing layer onto at least a portion of the bottom side of the face fabric; and    forming a bottom surface of the backing layer to create a plurality of fluid flow paths thereon at least a portion of the bottom surface, wherein at least one of the plurality of fluid flow paths extends to at least one side edge of the structure such that the backing layer dissipates moisture from between the bottom surface of the backing layer and the underlying flooring surface.    
   
   
       36 . The method of  claim 35 , wherein the step of forming the bottom surface comprises forming a plurality of spaced male protrusions, each male protrusion having a distal end and extending outwardly away from the bottom surface of the backing layer, whereby the plurality of fluid flow paths are defined therebetween the plurality of spaced male protrusions.  
   
   
       37 . The method of  claim 36 , wherein the bottom surface further defines a plurality of troughs, and wherein each trough forms a portion of a fluid flow path of the plurality of fluid flow paths.  
   
   
       38 . The method of  claim 36 , wherein the plurality of spaced male protrusions comprise a plurality of spaced parallel rows of substantially co-axial spaced male protrusions, each row extending along a row axis, wherein the bottom surface of the backing layer has a longitudinal axis, and wherein the row axis is offset rotationally relative to the longitudinal axis of the bottom surface at an acute angle α.  
   
   
       39 . The method of  claim 38 , wherein the male protrusions in adjacent parallel rows are staggered in relation to each other.  
   
   
       40 . The method of  claim 35 , further comprising, prior to the step of applying the backing layer, applying an adhesive layer to at least a portion of the bottom side of the face fabric, wherein the backing layer is applied to the adhesive layer.  
   
   
       41 . The method of  claim 40 , wherein the backing layer comprises a resilient spacer member, wherein the spacer member spaces the bottom side from the underlying flooring surface to dissipate moisture from beneath the bottom side, the plurality of fluid flow paths being defined therethrough the spacer member.  
   
   
       42 . The method of  claim 35 , further comprising, prior to the step of applying the backing layer, applying a first adhesive layer onto at least a portion of the bottom side of the face fabric, applying a reinforcing fabric layer onto at least a portion of the first adhesive layer, and applying a second adhesive layer onto at least a portion of the reinforcing fabric layer, wherein the backing layer is applied onto at least a portion of the second adhesive layer.  
   
   
       43 . The method of  claim 35 , wherein the step of forming the bottom surface of the backing layer occurs before the step of applying the backing layer onto at least a portion of the bottom side of the face fabric.  
   
   
       44 . A floor covering underlayment having at least one side edge, comprising: 
 a bottom surface having an longitudinal axis, a portion of the bottom surface of the floor covering underlayment having a plurality of spaced male protrusions extending therefrom, the bottom surface further defining a plurality of troughs therebetween the spaced male protrusions, wherein each trough forms a fluid flow path, and wherein at least one of the formed fluid flow paths extends to the at least side edge of the underlayment such that moisture can dissipate from between the bottom surface and an underlying flooring surface.    
   
   
       45 . The floor covering underlayment of  claim 44 , wherein the bottom surface has a longitudinal axis, wherein the plurality of spaced male protrusions comprises a plurality of spaced parallel rows of substantially co-axial spaced male protrusions, each row extending along a row axis, wherein the male protrusions in adjacent parallel rows are staggered in relation to each other, and wherein the row axis is offset rotationally in relation to the longitudinal axis of the bottom surface at an acute angle α.  
   
   
       46 . The floor covering underlayment of  claim 45 , wherein at least one of the plurality of troughs of a first piece of underlayment are in fluid communication with at least one of the plurality of troughs of an adjoining, second piece of underlayment when the first and second pieces of underlayment are adjoined on the underlying flooring surface.  
   
   
       47 . A carpet or carpet tile structure, the structure having at least one side edge comprising: 
 a face fabric having a bottom side; and    a backing layer having a top surface and an opposed bottom surface, wherein in the top surface of the backing layer is proximate to at least a portion of the bottom side of the face fabric, wherein at least a portion of the bottom surface of the backing layer defines a plurality of fluid flow paths that are suitable for allowing moisture dissipation when the structure is applied to an underlying flooring surface.