Polyurethane backed products and methods

Abstract

A surface covering such as a carpet, carpet tile, area rug, floor mat or the like incorporating a textile face disposed in contacting overlying relation to at least a polyurethane layer. One or more optional intermediate structure layers may be disposed within the polyurethane and one or more optional backing layers may be disposed across the underside of the polyurethane.

1 . A surface covering such as a floor covering comprising a textile face structure disposed in overlying contacting relation to a layer of filled polyurethane. 
   
   
       2 . The invention of  claim 1 , further comprising a backing disposed across a side of the layer of polyurethane facing away from the textile face structure. 
   
   
       3 . The invention of  claim 1 , further comprising a structural support layer disposed in embedded relation within the layer of polyurethane. 
   
   
       4 . The invention of  claim 1 , further comprising a structural support layer disposed in embedded relation within the layer of polyurethane and a backing disposed across a side of the layer of polyurethane facing away from the textile face structure. 
   
   
       5 . The invention of  claim 1 , wherein the surface covering is a carpet. 
   
   
       6 . The invention of  claim 1 , wherein the surface covering is a carpet tile. 
   
   
       7 . The invention of  claim 1 , wherein the surface covering is an area rug. 
   
   
       8 . The invention of  claim 1 I wherein the surface covering is a floor mat. 
   
   
       9 . A method of forming combinations of the group consisting of carpet, carpet tile, area rugs and floor mats on a single processing line, the method comprising the steps of:
 (a) delivering a mass of polyurethane forming composition onto an endless belt;   (b) leveling the polyurethane forming composition to a desired thickness;   (c) placing a preformed textile face structure into overlying contacting relation with the leveled polyurethane forming composition;   (d) curing the polyurethane forming composition in place across the underside of the textile face structure; and   (e) cutting the composite of textile face structure with cured polyurethane to at least two different sizes.