Abstract:
The present invention relates polyester tufted carpet where the tufts are engaged with a primary polyester backing and where a polyester extrusion coating is applied to the backside of the primary backing to lock the tufts which therefore avoids the use of a latex adhesive.
Abstract:
The present invention pertains to carpet and carpet tile. In one aspect, the carpet includes (a) a primary backing which has a face and a back surface, (b) a plurality of fibers attached to the primary backing and extending from the face of the primary backing and exposed at the back surface of the primary backing, (c) an adhesive backing, (d) an optional secondary backing adjacent to the adhesive backing, and (e) at least one non-chlorinated, non-polyvinyl butyral thermoplastic polymer or composition having a specific growth tension at 40 C and a specific residual stress at 25% strain. Additional steps and procedures include washing or scouring the primary backing and fibers prior to the extrusion step, and utilizing implosion agents. The preferred olefin block copolymer are ethylene based block interpolymers. The constructions and methods described herein are particularly suited for making tufted, broad-loom carpet having improved abrasion resistance.
Abstract:
A method for binding a greige carpet and a secondary backing material using a hot melt adhesive is disclosed. A heated application roll may be provided and the secondary backing material may be contacted with the hot melt adhesive and greige carpet and pressed against the heated application roll.
Abstract:
Tufted carpets bonded with thermoplastic binders and having improved resistance to fuzz formation due to removal of pile yarn filaments from tuft bundles comprise one or more backings, face yarn that forms a pile on one side and stitches on an opposite side, a thermoplastic binder that binds stitches and the backing or backings, and an organic polymer that bonds filaments of the stitches. Processes for making carpets comprise applying to a stitched side of a tufted backing a liquid stitch bind composition comprising an organic polymer component, removing a liquid component of the composition to bond filaments of the stitches and bonding stitches and one or more backings with a thermoplastic binder that is melted or applied as a melt in contact with the stitched side and the backing or backings and solidified.
Abstract:
A synthetic turf is made by providing a tufted material having a plurality of bundles of fibers extending outwardly from a front side thereof; providing a hot melt adhesive having a ring and ball softening point and heating the adhesive to a temperature corresponding to at least its ring and ball softening point; and applying the thus heated hot melt adhesive to a back side of the tufted material, wherein the adhesive cools to a temperature substantially below its ring and ball softening point after it has been applied to the back side of the tufted material. The thus treated material is preferably passed directly against and around a heated drum maintained at a temperature substantially corresponding to the ring and ball softening point of the hot melt adhesive to render the adhesive in a sufficiently plastic state such that the adhesive substantially penetrates into interstices of the bundles of fibers to substantially bind together each of the fibers of each of the bundles.
Abstract:
Carpet backings and use thereof in tufted carpets with good tuft bind and fuzz resistance and free of inorganic and latex materials are disclosed. Backings suitable as tuftable primary backings or as secondary backings have a nonwoven fabric with thermoplastic filaments and a thermoplastic supporting fabric operatively attached as by needling, thermal calendaring or point bonding.
Abstract:
A covering for a floor, wall or ceiling surface includes tiles each having first and second discrete tile sections. The first section includes a primary backing exposed on one side of the tile forming a first discrete exposed surface portion and a plurality of yarns tufted into the primary backing with cut or loop yarns on the back side of the primary backing leaving backstitches forming a second discrete exposed surface portion of the first section. The primary backing and backstitches form the first and second surface portions, respectively, of the first section with aesthetic characteristics different from one another. The second section of the tile is formed of one of a woven fabric, a non-woven fabric and a tufted pile and which second section forms the remaining portion of the exposed surface of the tile.
Abstract:
Improvements in preventing heat- and moisture-shrink problems in specific polypropylene tape fibers are provided. Such fibers are basically manufactured through the initial production of polypropylene films or tubes which are then slit into very thin, though flat (and having very high cross sectional aspect ratios) tape fibers thereafter. Such fibers (and thus the initial films and/or tubes) require the presence of certain compounds that quickly and effectively provide rigidity to the target polypropylene tape fiber after heat-setting. Generally, these compounds include any structure that nucleates polymer crystals within the target polypropylene after exposure to sufficient heat to melt the initial pelletized polymer and upon allowing such a melt to cool. The compounds must nucleate polymer crystals at a higher temperature than the target polypropylene without the nucleating agent during cooling. In such a manner, the nullrigidifyingnull nucleator compounds provide nucleation sites for polypropylene crystal growth. Upon slitting of the initial film and/or tube, the fiber is then exposed to sufficient heat to grow the crystalline network, thus holding the fiber in a desired position. The preferred nullrigidifyingnull compounds include dibenzylidene sorbitol based compounds, as well as less preferred compounds, such as sodium benzoate, certain sodium and lithium phosphate salts (such as sodium 2,2null-methylene-bis-(4,6-di-tert-butylphenyl)phosphate, otherwise known as NA-11). Specific methods of manufacture of such inventive tape fibers, as well as fabric articles made therefrom, are also encompassed within this invention.
Abstract:
Improvements in preventing heat- and moisture-shrink problems in specific polypropylene tape fibers are provided. Such fibers are basically manufactured through the initial production of polypropylene films or tubes which are then slit into very thin, though flat (and having very high cross sectional aspect ratios) tape fibers thereafter. Such fibers (and thus the initial films and/or tubes) require the presence of certain compounds that quickly and effectively provide rigidity to the target polypropylene tape fiber after heat-setting. Generally, these compounds include any structure that nucleates polymer crystals within the target polypropylene after exposure to sufficient heat to melt the initial pelletized polymer and upon allowing such a melt to cool. The compounds must nucleate polymer crystals at a higher temperature than the target polypropylene without the nucleating agent during cooling. In such a manner, the nullrigidifyingnull nucleator compounds provide nucleation sites for polypropylene crystal growth. Upon slitting of the initial film and/or tube, the fiber is then exposed to sufficient heat to grow the crystalline network, thus holding the fiber in a desired position. The preferred nullrigidifyingnull compounds include dibenzylidene sorbitol based compounds, as well as less preferred compounds, such as sodium benzoate, certain sodium and lithium phosphate salts (such as sodium 2,2null-methylene-bis-(4,6-di-tert-butylphenyl)phosphate, otherwise known as NA-11). Specific methods of manufacture of such inventive tape fibers, as well as fabric articles made therefrom, are also encompassed within this invention.
Abstract:
An improved cushioned carpet fabric is provided. The cushioned carpet comprises a primary carpet having a primary base and a plurality of pile-forming yarns projecting outwardly from one side. A layer of reinforcement material is bonded to the primary base on the side opposite the pile forming yarns. The reinforcement layer is adjacent to and embedded in, a cushion layer of a polymer such as a polyurethane. There is preferably no additional adhesive between the cushion layer and the layer of reinforcement material since the primary carpet fabric is mated in-situ to the polyurethane-forming composition without preheating the polyurethane-forming composition. An apparatus and process for forming the cushioned carpet fabric of the present invention are also provided.