Embossed carpet backing

Abstract

Disclosed is a floor covering having an embossed polyurethane foam backing layer and methods of making and using same. A bottom surface of the backing layer can be thermo-embossed with a predetermined pattern, and the bottom surface of the backing layer can define at least one fluid pathway in communication with a side edge of the floor covering. The floor covering can also have a layer of skid-resistant material connected to the bottom surface of the backing layer.

What is claimed is: 
     
         1 . A floor covering having a plurality of side edges, comprising:
 a greige good having a face surface and a back surface; and   an embossed backing layer having a top surface and an opposed bottom surface, wherein the top surface of the backing layer is connected to the back surface of the greige good, wherein the bottom surface of the backing layer is thermo-embossed with a pre-determined pattern, the predetermined pattern comprising a plurality of discrete spaced male projections extending away from a plane positioned within the partially cured polyurethane composition and oriented substantially parallel to the back surface of the greige good, wherein each male projection has a top surface, wherein adjacent male projections of the plurality of discrete spaced male projections cooperate to define a plurality of fluid pathways, wherein each fluid pathway is in communication with at least one side edge of the floor covering and configured to disperse fluid to the at least one side edge of the floor covering; and wherein each top surface of the plurality of discrete spaced male projections has a layer of skid-resistant material cured thereto,   wherein the embossed backing layer is made by metering a foamable polyurethane composition to the back surface of the greige good to form a substantially uniform layer of the foamable polyurethane composition having a predetermined thickness, partially curing the foamable polyurethane composition, wherein the step of partially curing the foamable polyurethane composition comprises substantially curing at least about 60% of the foamable polyurethane composition, embossing the partially cured polyurethane composition to define the predetermined pattern, curing the embossed polyurethane composition, applying the layer of skid-resistant material to only the top surface of the plurality of discrete spaced male projections of the cured embossed polyurethane composition; and curing the layer of skid-resistant material,   wherein the steps of partially curing the foamable polyurethane composition, curing the embossed polyurethane composition, and curing the layer of skid-resistant material are each separately performed in a belted oven.   
     
     
         2 . The floor covering of  claim 1 , wherein the plurality of discrete spaced male projections comprises a plurality of raised serpentine bands. 
     
     
         3 . The floor covering of  claim 2 , wherein the plurality of raised serpentine bands comprises a plurality of substantially parallel raised serpentine bands. 
     
     
         4 . The floor covering of  claim 1 , wherein the oven is a triple-pass oven. 
     
     
         5 . The floor covering of  claim 1 , wherein the step of partially curing the foamable polyurethane composition is performed in a first pass through the oven, wherein the step of curing the embossed polyurethane composition is performed in a second pass through the oven, and wherein the step of curing the layer of skid-resistant material is performed in a third pass through the oven. 
     
     
         6 . The floor covering of  claim 1 , wherein the cross-sectional surface area of the distal ends of the plurality of discrete spaced male projections is at least 20% of the cross-sectional area of the bottom surface of the backing layer. 
     
     
         7 . The floor covering of  claim 1 , wherein the cross-sectional surface area of the distal ends of the plurality of discrete spaced male projections is at least 40% of the cross-sectional area of the bottom surface of the backing layer. 
     
     
         8 . The floor covering of  claim 1 , wherein the cross-sectional surface area of the distal ends of the plurality of discrete spaced male projections is at least 60% of the cross-sectional area of the bottom surface of the backing layer. 
     
     
         9 . The floor covering of  claim 1 , wherein the cross-sectional surface area of the distal ends of the at least one male projection is at least 80% of the cross-sectional area of the bottom surface of the backing layer. 
     
     
         10 . The floor covering of  claim 1 , wherein the backing layer has a depth of between about 0.1 inch to 0.5 inch. 
     
     
         11 . The floor covering of  claim 10 , wherein the backing layer has a weight between about 10 to about 50 ounces per square yard. 
     
     
         12 . The floor covering of  claim 10 , wherein the backing layer has a weight between about 20 to about 40 ounces per square yard. 
     
     
         13 . The floor covering of  claim 10 , wherein the backing layer has a density between about 8 to about 22 pounds per cubic foot. 
     
     
         14 . The floor covering of  claim 10 , wherein the backing layer has a density between about 12 to about 14 pounds per cubic foot. 
     
     
         15 . The floor covering of  claim 10 , wherein each male projection of the at least one male projection has a length of between about 0.05 inch to 0.25 inch. 
     
     
         16 . The floor covering of  claim 1 , wherein the greige good comprises polypropylene. 
     
     
         17 . The floor covering of  claim 1 , wherein the greige good comprises a non-woven primary backing 
     
     
         18 . The floor covering of  claim 1 , wherein the greige good comprises a woven primary backing 
     
     
         19 . The floor covering of  claim 1 , wherein the skid-resistant material comprises an acrylic polymer. 
     
     
         20 . The floor covering of  claim 19 , wherein the skid-resistant material comprises an acrylic polymer blended with water at a ratio of greater than 50% solids to water. 
     
     
         21 . The floor covering of  claim 1 , wherein at least a portion of the greige good comprises reclaimed materials. 
     
     
         22 . A floor covering having a plurality of side edges, comprising:
 a greige good having a face surface and a back surface; and   an embossed backing layer having a top surface and an opposed bottom surface, wherein the top surface of the backing layer is connected to the back surface of the greige good, wherein the bottom surface of the backing layer is thermo-embossed with a pre-determined pattern, the predetermined pattern comprising a plurality of discrete spaced male projections extending away from a plane positioned within the partially cured polyurethane composition and oriented substantially parallel to the back surface of the greige good, wherein each male projection has a top surface, wherein adjacent male projections of the plurality of discrete spaced male projections cooperate to define a plurality of fluid pathways, wherein each fluid pathway is in communication with at least one side edge of the floor covering and configured to disperse fluid to the at least one side edge of the floor covering; and wherein each top surface of the plurality of discrete spaced male projections has a layer of skid-resistant material cured thereto,   wherein the embossed backing layer is made by metering a foamable polyurethane composition to the back surface of the greige good to form a substantially uniform layer of the foamable polyurethane composition having a predetermined thickness, partially curing the foamable polyurethane composition, wherein the step of partially curing the foamable polyurethane composition comprises substantially curing at least about 60% of the foamable polyurethane composition, embossing the partially cured polyurethane composition to define the predetermined pattern, curing the embossed polyurethane composition, applying the layer of skid-resistant material to only the top surface of the plurality of discrete spaced male projections of the cured embossed polyurethane composition; and curing the layer of skid-resistant material,   wherein the step of partially curing the foamable polyurethane composition is performed in a first pass through an oven, wherein the step of curing the embossed polyurethane composition is performed in a second pass through the oven, and wherein the step of curing the layer of skid-resistant material is performed in a third pass through the oven.   
     
     
         23 . The method of  claim 22 , wherein the plurality of discrete spaced male projections of the predetermined pattern comprises a plurality of raised serpentine bands. 
     
     
         24 . The floor covering of  claim 22 , wherein the cross-sectional surface area of the top surfaces of the plurality of discrete spaced male projections is at least 40% of the cross-sectional area of a bottom surface of the floor covering.