Carpet construction and carpet backings for same
Tufted carpet having good tuft bind and fuzz resistance comprising pile face yams, a backing fabric and an adhesive binder free of inorganic and latex materials. The adhesive binder comprises a thermoplastic fabric, which melts to secure the pile to the backing.
1 - 14 . (canceled)
15 . A primary carpet backing consisting of a nonwoven adhesive fabric needled or thermally bonded to a supporting fabric, wherein the carpet backing is tuftable with carpet face yarn and the nonwoven adhesive fabric is a self-bonded or spunbonded nonwoven fabric comprising substantially continuous filaments of a thermoplastic resin and the supporting fabric is a tuftable woven primary backing fabric comprising thermoplastic warp and weft yarns having substantially rectangular cross-sections.
16 - 39 . (canceled)
40 . The primary carpet backing of claim 15 in which the supporting fabric is a polyolefin fabric.
41 . The primary carpet backing of claim 40 in which the supporting fabric is woven from polypropylene yarns.
42 . The primary carpet backing of claim 41 in which the nonwoven fabric is a spunbonded fabric.
43 . The primary carpet backing of claim 41 in which the nonwoven fabric is a self-bonded fabric.
44 . The primary carpet backing of claim 41 in which the substantially continuous filaments comprise a thermoplastic resin having a melting point at least about 20° C. less than the melting point of the thermoplastic resin of the yarns of the supporting fabric.
45 . The primary carpet backing of claim 15 tufted with carpet face yarn.
46 . A primary carpet backing that is tuftable with carpet face yarn comprising a nonwoven adhesive fabric needled or thermally bonded to a supporting fabric, wherein the supporting fabric is a tuftable woven primary backing fabric comprising thermoplastic warp and weft yarns having substantially rectangular cross-sections and the nonwoven adhesive fabric comprises fibers or filaments of a thermoplastic resin having a melting point at least about 20° C. less than the melting point of the thermoplastic of the yarns of the supporting fabric.
47 . The primary carpet backing of claim 46 in which the supporting fabric is a polyolefin fabric.
48 . The primary carpet backing of claim 46 in which the supporting fabric is woven from polypropylene yarns.
49 . The primary carpet backing of claim 48 in which the nonwoven adhesive fabric is a spunbonded fabric.
50 . The primary carpet backing of claim 48 in which the nonwoven adhesive fabric is a self-bonded fabric.
51 . The primary carpet backing of claim 48 in which the nonwoven adhesive fabric is a needlepunched nonwoven fabric.
52 . The primary carpet backing of claim 46 in which the nonwoven adhesive fabric comprises staple fibers.
53 . The primary carpet backing of claim 46 in which the nonwoven adhesive fabric comprises continuous filaments.
54 . The primary carpet backing of claim 46 tufted with carpet face yarn.