Floor covering with universal backing and methods of making and recycling

1. A method of manufacturing a universal floor covering which can be used as either a broadloom or modular floor covering, the method comprising the steps of:

selectively manufacturing either a broadloom or modular floor covering from a group of design components including a tufted textile substrate having a primary backing substrate extending in a first direction and a plurality of yarns tufted through the primary backing substrate, the primary backing substrate having a face side and a back side opposite the face side, a portion of each yarn forming a stitch portion having an end that is located on the back side of the primary backing substrate, and an interstitial space existing between the ends of stitch portions;

said group of design components further including a composition pool having a mixture of adhesive and reinforcement fibers, and said group of design components being collectively and individually designed to have desired performance characteristics;

moving the tufted textile substrate relative to an applicator and providing space between the stitch portions of the yarns and the applicator;

applying pressure in a controlled manner between the applicator and tufted textile substrate and forcing the adhesive and reinforcement fiber composition in a second direction that is toward the back side of the primary backing substrate;

aligning the reinforcement fibers to lay predominantly in the first direction such that the reinforcement fibers form a reinforcement layer of fibers that is substantially parallel to the first direction for providing dimensional stability for the entire floor covering and for forming a universal floor covering that can be used as either a broadloom or modular floor covering;

applying a vacuum to the composition pool before aligning the reinforcement fibers to lay predominantly in the first direction;

curing the universal floor covering; and

selectively cutting the universal floor covering depending on whether it is desired to install a broadloom or modular floor covering, and rolling the cut universal floor covering into a roll for shipment and installation.

2. The method of manufacturing a floor covering according to claim 1 further comprising selectively cutting the universal floor covering for forming multiple locking patterns at designated intervals along the length of the floor covering.

3. The method of manufacturing a floor covering according to claim 1 further comprising selectively cutting the universal floor covering at designated intervals along the length of the floor covering.

4. The method of manufacturing a floor covering according to claim 1 further comprising selectively operating the vacuum for causing the movement of fibers into the spaces between the stitch portions before applying pressure between the applicator and tufted textile substrate.

5. The method of manufacturing a floor covering according to claim 1 further comprising mixing the adhesive and reinforcement fibers before aligning the fibers to lay predominantly in the first direction.

6. The method of manufacturing a floor covering according to claim 1 further comprising forming a cushion or friction layer on the reinforcement layer of fibers before cutting the universal floor covering.

7. The method of manufacturing a floor covering according to claim 1 further comprising forming a cushion or friction roll the same length and width as the universal floor covering.

8. A method of manufacturing a universal floor covering which can be used as either a broadloom or modular floor covering, the method comprising the steps of:

selectively manufacturing either a broadloom or modular universal floor covering from the same group of design components including a tufted textile substrate having a primary backing substrate extending in a first direction and a plurality of yarns tufted through the primary backing substrate, the primary backing substrate having a face side and a back side opposite the face side, a portion of each yarn forming a stitch portion having an end that is located on the back side of the primary backing substrate, and an interstitial space existing between the ends of stitch portions; and the characteristics of each design component, including a length of the fibers, a diameter of the fibers, a viscosity of the adhesive, a porosity of the fiber and the adhesive, being selected to meet desired performance characteristics;

selecting an equipment arrangement for applying a pool of adhesive and reinforcement fibers to said tufted textile substrate;

conditioning the adhesive and fibers to assist in preparing the adhesive and fibers to be in a desired condition and location in the pool of adhesive and fibers;

moving the tufted textile substrate relative to an applicator and applying pressure in a controlled manner between the applicator and tufted textile substrate and forcing the adhesive and reinforcement fibers in a second direction that is toward the back side of the primary backing substrate;

aligning the reinforcement fibers to predominantly lay in the first direction such that the reinforcement fibers form a reinforcement layer of fibers that is substantially parallel to the first direction for providing dimensional stability for the entire floor covering and for forming a universal floor covering that can be used as either a broadloom or modular floor covering;

applying a vacuum to the pool of adhesive and reinforcement fibers before completing the alignment of the reinforcement fibers;

curing the universal floor covering; and

selectively cutting the universal floor covering depending on whether it is desired to have a roll of broadloom floor covering, a roll of modular floor covering, or a combination roll having both broadloom and modular floor coverings; and rolling the universal floor covering into a roll for shipment and installation.

9. The method of manufacturing a universal floor covering according to claim 8 further comprising using the vacuum to move fibers into the spaces between the stitch portions and applying pressure between the applicator and tufted textile substrate to form the layer of reinforcement fibers.

10. The method of manufacturing a universal floor covering according to claim 8 further comprising applying the vacuum to move adhesive into the back side of the primary backing substrate.

11. The method of manufacturing a universal floor covering according to claim 8 further comprising selectively mixing the pool of adhesive and reinforcement fibers, selectively injecting air into the pool of adhesive and reinforcement fibers, or selectively applying a vacuum to the pool of adhesive and reinforcement fibers.

12. The method of manufacturing a universal floor covering according to claim 8 wherein the equipment arrangement includes engaging the applicator with the pool of adhesive and reinforcement fibers or engaging the applicator with the tufted textile substrate, and wherein the applicator applies pressure in a controlled manner for causing the adhesive and reinforcement fibers to move toward the backside of the primary facing substrate.

13. The method of manufacturing a universal floor covering according to claim 8 further comprising selectively cutting the universal floor covering by forming multiple locking patterns at designated intervals along the length of the floor covering or by cutting the universal floor covering at designated intervals along the length of the floor covering.

14. The method of manufacturing a universal floor covering according to claim 13 further comprising providing at least one cushion or friction layer on the reinforcement layer of fibers, said layer is formed and cut either with the cutting of the universal floor covering or said layer is formed and cut from a cushion or friction roll to match the cuts on the universal floor covering.

15. The method of manufacturing a universal floor covering according to claim 8 wherein the adhesive is dissolvable for allowing recycling of the floor covering when necessary by dissolving the adhesive between the reinforcement layer of fibers and the backing substrate for allowing the yarns, textile substrate, reinforcement fibers, and adhesive to be separated and recycled.