US 11,814,785 B2
Reinforced polymeric nonwoven mat for carpet tiles
Heath H Himstedt, Littleton, CO (US); Souvik Nandi, Highlands Ranch, CO (US); and Philip Christopher Sharpe, Centennial, CO (US)
Assigned to Johns Manville, Denver, CO (US)
Filed by JOHNS MANVILLE, Denver, CO (US)
Filed on Jan. 20, 2023, as Appl. No. 18/099,399.
Application 18/099,399 is a division of application No. 17/085,060, filed on Oct. 30, 2020, granted, now 11,618,997.
Prior Publication US 2023/0151540 A1, May 18, 2023
Int. Cl. D06N 7/00 (2006.01)
CPC D06N 7/0081 (2013.01) [D06N 7/0076 (2013.01); D06N 7/0078 (2013.01); D06N 7/0086 (2013.01); D06N 2201/0254 (2013.01); D06N 2201/082 (2013.01); D06N 2209/1628 (2013.01); D06N 2211/066 (2013.01); Y10T 428/23979 (2015.04)] 18 Claims
OG exemplary drawing
 
1. A method of manufacturing a carrier mat for carpet tiles, the method comprising:
forming a first layer of polymer fibers that are randomly oriented and entangled together;
positioning a reinforcement atop the first layer of polymer fibers;
forming a second layer of polymer fibers atop the reinforcement so that the reinforcement is entirely covered and concealed by the first layer of polymer fibers and the second layer of polymer fibers;
applying a binder to the first layer of polymer fibers, the reinforcement, and the second layer of polymer fibers; and
heating the first layer of polymer fibers, the reinforcement, and the second layer of polymer fibers to cure the binder to adhere the first layer of polymer fibers, the reinforcement, and the second layer of polymer fibers together;
wherein the binder is uniformly distributed throughout the carrier mat to bond the first layer of polymer fibers, the reinforcement, and the second layer of polymer fibers together; and
wherein the binder is the only binder that is used to bond the carrier mat together.