Energy-activated coating and method for manufacturing a carpet with an energy-activated coating

Abstract

An energy-activated adhesive may be applied to a carpet backing before tufting a yarn through the backing. The energy-activated adhesive may be pre-gelled, gelled, melted, or partially melted to flow into the yarn and the backing and / or be cured to secure the tufts to the carpet backing and to provide a specific tack and / or a specific adhesion. The curing step may be initiated by exposing the energy-activated adhesive to heat, radiation, or their combinations. In some embodiments, the energy-activated formulation may be printed onto the yam, the backing, or both. The steps of exposing the carpet backing with the energy-activated adhesive may be varied in a number of ways including the use of lasers, masers, and other guided energy beams. The carpet backing may then be processed to form a soft surface article.

Description

[0001] Energy-activated coating and method for manufacturing a carpet with an energy- activated coating

[0002] The present invention relates to an energy-activated coating and a method for manufacturing soft surface article with an energy-activated coating.

[0003] CROSS-REFERENCE TO RELATED APPLICATIONS

[0004] The present application claims the benefit of priority of U.S. Patent Application 63 / 627,088, the contents of which is hereby incorporated by reference for all purposes.

[0005] BACKGROUND

[0006] Currently many flooring products, such as but not limited to soft surfaces including carpet, rugs, carpet tiles, and the like, utilize a coating comprised of a water-based dispersion or emulsion formulation which, in the case of the exemplary soft surface articles, holds the tufts of carpet from being pulled out because the backstitches of the tufts adhere to the coating placed upon the back side of the backing material. In many cases, the water-based dispersions or emulsion formulations are traditional latex compositions.

[0007] In this, a griege is first made by tufting pile yarn through a primary backing. The backstitches will be loose in the griege until they are anchored in place. This is usually done by applying and curing a traditional latex formulation onto the back of the griege. A traditional latex formulation applied onto the backstitches and the back of the primary backing for anchoring the backstitches is usually referred to as a precoat.

[0008] After the griege has a water-based formula applied as a liquid, it must pass through a series of drying ovens to evaporate the water from the formulation and to cure the traditional latex. Drying and curing the traditional latex requires significant amounts of heat to be generated and applied to the soft surface article for this purpose. In some cases, the heat is not recovered but is allowed to dissipate as waste heat.

[0009] In other embodiments, a hot melt adhesive may be used instead of, or in conjunction with a water-based dispersion to secure the backstitching of the yarn to the primary backing material.

[0010] However, new adhesives are being developed that cure and / or harden with the application of different forms of energy. Some of these adhesives may be formulated to be non-adhesive or semi-adhesive as they are being applied, and only become adhesive when a specific type of energy is applied to activate them. In one aspect, some adhesives may be cured through the application of radiation. In another aspect, some adhesives may be cured through the application of heat. In another aspect, some adhesives may be activated through the use of radiation and cured through the use of heat, and vise versa. Adhesives of any type may be used as detailed herein within the scope of the inventions disclosed and taught.

[0011] Many types of radiation may be used to cure or set radiation-activated formulations. Throughout this specification, it must be understood that using the specific terms such as “UV”, “IR”, “ultraviolet”, “visible”, “infrared”, “microwave”, and other references to specific wavelengths of radiation are only exemplary embodiments of the many embodiments that are within the scope of the inventions disclosed and taught herein.

[0012] In a similar way, many types of heat-activated formulations may be used within the inventions disclosed and taught herein. Broadly, these do not include traditional latex formulations where the energy applied is heat that will cure the traditional latex while driving off the water carrier. In embodiments that are preferred within the scope of this disclosure, heat-activated formulations are those that are not traditional latex formulations. For example, and without limitation, a two-part adhesive may be considered to be a preferred embodiment. In this, one part of the two-part formulation may be applied to a yam to be tufted while the second part of the two-part formulation may be applied to the backing which will be tufted with the yam. These two parts of the exemplary two-part formulation will not bond, adhere, or react to each other when they are contacted. However, after the tufting operation is complete, heat or radiation may be applied to activate the two-part formulation such that in the areas where the yarn and the backing meet, the components of the two-part formulation react to create a bond that will anchor the tufts to the backing.

[0013] The two-part formulations disclosed and taught herein are unlike traditional poly epoxides (e.g., epoxies) in that the two-part formulations preferred herein are essentially non-reactive with each other until such time that they are heated.

[0014] Similarly, traditional synthetic and natural latexes are cured when their dispersant (e.g., water) is evaporated leaving the monomers and / or resins to react and crosslink. However, within the scope of the inventions disclosed and taught herein, it is preferred to use formulations that contain oligomers, perhaps with some monomers, that do not react when applied, but will react to link and cross-link when heat and / or radiation is applied.

[0015] Also, current embodiments of applying traditional latex and hot melt adhesives generally spread the adhesive across the entirety of the backing to be tufted. While these methods ensure that adhesive will be spread to all areas where the backstitching of the yarn will contact the back side of the backing to be tufted, it may be considered wasteful. Also, if the cured and / or dried adhesive is stiff, it may promote unwanted characteristics to the resulting soft surface article. For example, if the cured and / or dried adhesive is stiff and / or brittle, it may prevent the soft surface article from being rolled into a cylinder for packaging and transportation. As another example, if the cured and / or dried adhesive is brittle, it may cause an irritating crunchy feeling and sound when people walk across it.

[0016] In some embodiments, using a traditional latex as a pre-coat or a skip coat may add a type of polymer that exhibits strong tuft binding, but renders the soft surface article less recyclable. For example, a carpet may be made of polyethylene terephthalate (PET) components, including the pile yarn, the primary backing, and any secondary backings. However, a PET-based adhesive may not exhibit the tuft binding strength needed to pass quality tests and to meet consumer expectations. To achieve those goals, a vinyl latex may be required, such as one that yields polyvinyl chloride (PVC). If the application of a vinyl latex adds enough PVC as a pre-coat, the carpet may be uneconomical to recycle since the cost of separating the PVC from the recyclable PET may be excessively prohibitive.

[0017] Some publications of these methods include the following:

[0018] Publication WO 2020 / 095196 Al discloses: “Coated panel with at least a substrate (2) and a top layer applied thereto (3), wherein the above-mentioned top layer (3) comprises at least a decor layer (4) and a translucent or transparent wear layer (5), characterized in that the above-mentioned wear layer (5) comprises a thermally cured acrylate resin or a thermally cured unsaturated polyester resin. Preferably, wherein thermal curing partially or completely cures the resin. In particular, wherein the above-mentioned acrylate resin or unsaturated polyester resin is at least partially cured by means of a thermally initiated radical crosslinking reaction. The invention further relates to a method for the production of such coated panels (1), in particular floor panels.”

[0019] Publication WO 2021 / 224843 Al discloses: “A sheet comprises a support layer and a coating layer on a side of the support layer. The coating layer is partially cured. The coating layer comprises carbon-carbon double bonds, wherein the relative amount of carbon-carbon double bonds is higher at the surface of the coating layer than at the contact surface of the coating layer with the support layer. Methods are disclosed to manufacture such sheets; and to produce a decorative panel using such sheets.”

[0020] Publication WO 2023 / 072891 Al discloses: “The present invention is directed to a radical-curable coating composition comprising (A) One or more oligomers selected from the group consisting of urethane (meth) acrylates, (meth)acrylated epoxidized triglycerides and any mixture thereof, wherein said oligomers have a molar mass equal to or higher than 800 g / mol and lower than 4500 g / mol, (B) One or more methacrylate reactive diluents having a molar mass lower than 800 g / mol, wherein said methacrylate reactive diluents have an average methacrylate functionality higher than 2, (C) One or more acrylate reactive diluents having a molar mass lower than 800 g / mol, wherein said acrylate reactive diluents have an average acrylate functionality higher than 2, (D) One or more photo-initiators, and (E) One or more thermal initiators, wherein the acrylate functionalities of the acrylate reactive diluents (C) and the methacrylate functionalities of the methacrylate reactive diluents (B) are present in a molar ratio of the acrylate functionalities to the methacrylate functionalities of at least 0.2, wherein the amount of oligomers (A) is higher than 20 wt.% and lower than 90 wt.% and the amount of reactive diluents (B) and (C) is higher than 10 wt.% and lower than 80 wt.%, based on the total amount of (A), (B) and (C), and wherein the total amount of (A), (B) and (C) is at least 25 wt.% of the radical-curable coating composition.”

[0021] European Patent publication No. 2 154 184 Al discloses: “The process comprises producing matt varnish for depositing on a thin layer, regulating a floor coating on a constitutive structure for treating its surface by reticulation using excimer type monochromatic radiation lamp (14), and cross-linking the floor and wall coatings in a chamber under inert atmosphere using UV light. The matt varnish is deposited in the thin layer having a thickness of 8-20 mu m. Independent claims are included for: (1) an installation for varnishing floors and flexible walls; and (2) a flexible floor and wall coating.”

[0022] U.S. Patent No. 2,748,446 claims: “The method of making a rug of the class described, which comprises applying to the undersurface of a fabric backing having closely spaced tufts producing a tufted outer surface, a coating of a fluid composition consisting essentially of a dispersion of resilient granular particles having a size between approximately 5 and 40 mesh and an aqueous elastomeric latex, the ratio of granular particles to latex solids being between approximately 0.5: 1 and 4: 1, and thereafter drying said coating to produce a non-cellular matrix which adheres to said fabric so as to anchor said tufts and provide a reinforcement for said fabric, said granular particles producing a relatively rough, resilient surface, the dry weight of said matrix and granular particles being between approximately 16 and 48 ounces per square yard.”

[0023] U.S. Patent No. 2,567,951 claims: “A combination material consisting of a textile layer and a fire resistant layer of vulcanized sponge rubber which contains sodium silicate, said textile material having a napped surface and said sponge rubber penetrating the interstices of said textile layer and firmly anchoring the threads of said nap.” U.S. Publication No. 2003 / 0068465 discloses: “A tufted carpet included a backing bonded to a tufted base with a layer of adhesive containing powder of a far-infrared radiating material. The adhesive layer not only prevents water on the upper surface of the carpet from penetrating through the carpet to the bottom of the carpet, but also warms the carpet so that the water can be evaporated.”

[0024] U.S. Patent No. 3,669,779 discloses: “Method of back-coating pile carpet containing pile yarns bound by embedment in a relatively impervious polymer layer comprising the steps of perforating the impervious layer to permit passage of gases therethrough, and applying a heat bondable polymeric back-coating to the perforated carpet.”

[0025] U.S. Patent No. 12,123,121 Al discloses: “Method for manufacturing a carpet or a rug, comprising the following steps: the step (S1-S2) of providing a primary backing (1), being a woven or non-woven layer comprising filaments (2) of polyethyleneterephthalate and copolymer of polyethyleneterephthalate, the coPET having a lower melting temperature than the PET and wherein said PET is available in said primary backing (1) in a higher amount than said coPET; the step of providing a glue layer (11) consisting for 50% or more out of coPET; the step of tufting yarn at least into said primary backing (1); the step of activating said glue layer (11) at least for partially fixing said yam (12) on said primary backing (1). The invention also concerns carpets (16) and mgs that are obtained or obtainable by means of such method.”

[0026] European Patent publication No. 4 467 702 Al discloses: “The present invention relates to a method of manufacturing a tufted textile, in particular configured as a floor covering, such as a carpeted floor or artificial gras. The method comprises the following steps:- Providing (40) a primary backing (12) with a tufting yarn (14) arranged partially extending through the primary backing (12);- Thermal fixation (42) of the tufting yarn (14) to the primary backing (12) with electromagnetic radiation, in particular a laser beam (22). The invention further relates to a tufted textile and a tufted textile manufacturing plant.”

[0027] The contents of these publications are incorporated by reference herein for all purposes. BRIEF SUMMARY

[0028] Energy-activated formulations disclosed and taught in light of the inventions claimed herein may include radiation-activated formulations and heat-activated formulations. While each has their own benefits, they may be applied in similar ways and exhibit similar properties when used with soft surface articles.

[0029] Throughout this disclosure, the term energy-activated formulation will refer to a formulation that may be activated by exposure to an energy source. Activating an energy-activated formulation means that the formulation may melt, partially melt, become molten, gel, pre-gel, become flowable, flow, cure, fix, polymerize, cross-link polymer chains, or harden. While and after an energy-activated formulation is activated, it may act as an adhesive to bond with fibers and filaments in a soft surface article. This includes anchoring the filaments or fibers of a pile yam to the primary backing. In one of many embodiments, this adhesive property may secure yam to a backing. In a preferred embodiment, the pile yarn may be anchored to the carpet substrate using the methods and applications disclosed and taught herein such that no other adhesives are required for the soft surface article to provide superior tuft binding properties and to meet all required tests.

[0030] While these formulations may be applied over an entire surface of a primary backing, Applicant has found ways of only applying energy-activated formulations to precise and desired locations. Once activated, the energy-activated formulations will bond tufted yarn to a primary backing. In accordance with preferred embodiments the formulation or adhesive is applied in a spatially distributed manner to prevent the soft surface article from becoming overly rigid or inflexible if the formulation or adhesive becomes rigid or hard when it is cured or dried. Even when an inflexible formulation or adhesive is used, its spatial distribution may result in an overall desirable flexibility of the soft surface article. Radiation-activated Formulations

[0031] As an alternative to applying traditional flexible coatings (such as a water-based dispersion (e.g., a latex) or a hot melt adhesive), radiation-activated adhesive formulations, which may also be called radiation-reactive formulations, may be applied and cured rapidly with relatively few irradiating stations at speeds that are comparable to, or faster than, curing or hardening a traditional latex or hot melt adhesive. This would eliminate the need to run multiple drying ovens and operations to evaporate water from, and to cure traditional latex dispersions used today on carpet backings. The inventions disclosed and taught herein have the potential to reduce cost, reduce manufacturing steps, and improve product quality for all soft surface articles. The inventions disclosed herein may provide an advantage to soft surface articles that are further treated with steam treatments such as in dyeing operations where delamination of a water-soluble traditional latex polymer due to re-dissolution of the polymer may occur.

[0032] Similarly, using a radiation-activated adhesive may make the entire soft surface product more recyclable.

[0033] In certain embodiments, the formulation may also act to adhere additional optically transparent or translucent backing layers having or not having coloration included. Such optically transparent or translucent backings may be applied as a sheet or a powder. A coloration may be produced through adding a colorant, dye, or by any other means known to those of ordinary skill in the art. Configuring the surface roughness or smoothness of such a back coating may also provide better adhesion to any additional backing layers. This also has potential to improve adhesion to the base floor or to provide anti-skid properties.

[0034] As an alternative, a pad, such as a woven or nonwoven fabric may be applied to the back of a griege, where the activation of the radiation-activated adhesive formulation may also secure the pad to the griege. Similarly to the optically transparent or translucent backings just described, the woven or nonwoven fabric may be transparent or translucent to the radiation applied to cure or set the radiation-activated adhesive formulation. In one of many embodiments that will be understood by those of ordinary skill in the art and in possession of the disclosures and teachings herein, several heating / drying ovens may be reduced to very few, or perhaps just one irradiating station. In this, a radiation-activated formulation may be applied as a powder, a paste, a tacky strip, or as a liquid and then passed through one irradiating station to melt it into place. This step may be followed by an exposure to additional radiation, which would then cure the radiation-activated formulation and thereby anchor the backstitches of the tufts to the backing. Those of ordinary skill in the art will understand that the process step of melting the radiation-activated formulation may be combined with, or separated from the process step of curing the radiation-activated formulation.

[0035] As one of many possible embodiments, the radiation-activated formulation may comprise a substance that melts, or becomes molten, or pre-gels when irradiated and then cures as the radiation is continually applied. This may be preferable in an embodiment where the radiation-activated formulation is applied to the backing and the yarn tufted over the radiation-activated formulation. Once applied and the backing is tufted, a first irradiation of the tufted backing may occur to melt or pregel the radiation-activated formulation so that it diffuses into the yam and the backing. Once the radiation-activated formulation has seeped or flowed into the yarn and the backing to a desired degree, it may be cured to anchor the yarn to the backing so that it passes required delamination and tuft pull tests. In another embodiment, a first application of radiation energy may melt or pre-gel the radiation-activated formulation. The backstitching of the yarn may then be pressed into the molten or pre-gelled radiation-activated formulation, and then a second radiation may be applied to cure the radiation-activated formulation.

[0036] Also encompassed within the inventions disclosed and taught herein are embodiments where the radiation-activated formulation may comprise a substance that melts and spreads when irradiated and another substance that cures and sets when irradiated. These may react to different frequencies or wavelengths of radiation. Therefore, a first step may be to apply the formulation; the second step may be to irradiate the applied formulation from a radiation source at a frequency that melts and spreads the radiation-meltable component; and a third step of irradiating the applied and melted formulation from a radiation source that cures the radiation- activated component. The radiation source in the second and third steps may be the same radiation source, or they may be different radiation sources.

[0037] Also encompassed within the inventions disclosed and taught herein are embodiments where one component heats when exposed to radiation to thereby cause a heat-activated formulation to activate. Those of skill in the art, and in possession of the teachings and disclosures herein, will be understand that radiation and heat may be applied together or in separate steps to achieve a reaction that binds backstitches so as to anchor them.

[0038] As those ordinarily skilled in the art will appreciate, the amounts of radiation applied in the second and third steps may be precisely applied to produce reproducible results. For example, and without limitation, the step of irradiating the applied formulation to melt or pre-gel the formulation may be stopped when the formulation becomes molten and has penetrated the fibers and backing to a desirable amount. This desirable amount may be to an extent that the flowable formulation has seeped through the pores in the matrix of the backing to coat at least some portion of the matrix without further advancing into the pile. In some situations, it may be desirable to not have any set / cured adhesive in the base of any tufts in the pile, which may produce an uncomfortable feeling on skin such as bare feet when walked across. Similarly, the third step of irradiating the formulation may involve stopping the radiation when the radiation-activated formulation has cured to a state that has desirable properties such as, but not limited to tack, adhesion, and flexibility.

[0039] The radiation-activated formulation may comprise an initiator, such as a photoinitiator. As disclosed herein, in some embodiments, a thermo-initiator may also be in the formulation. Those of ordinary skill in the art may understand that some types of radiation-activated formulations that may be used with the inventions disclosed and taught herein may have a higher efficacy when a photo-initiator is used within the formulation, or is applied during any of the steps described herein.

[0040] The radiation-activated formulation may also include other components to produce a desirable end result. One envisioned embodiment may include an anti-skid component. In this envisioned embodiment, the radiation-activated formulation may comprise a component that melts or becomes molten and flowable when irradiated at a specific wavelength or frequency; a component that cures when irradiated at the same or at a different wavelength; and a component that may form an anti-skid layer. The component used to form an anti-skid layer may have a density different from the other components. In this embodiment, the formulation may be applied to the backing of the carpet section while the backing is facing up and the tufts are facing downwards. In this orientation, gravity may be used to apply the formulation.

[0041] To illustrate this embodiment, the formulation may be applied from above the backing so that it falls onto the backing. This may include, but not be limited to spraying the formulation in a powder, granule, paste, spray, or liquid form onto the backing. The process step of irradiating the formulation may melt the formulation as described elsewhere herein such that the molten formulation seeps and or is wicked further down into the matrix of the backing and, if desired, to some extent further into the matrix of the backing. At the same time, particles of the component that may form the anti-skid layer may have a different density than the other components such that they rise to the top of the molten formulation and becomes exposed on the surface. After the step that melts the formulation is complete, there may be enough of an anti-skid component on the top surface of the carpet backing to provide desirable anti-skid properties to the finished soft surface article. The process may be continued by irradiating the formulation to cure the formulation. This may then set the anti-skid component and adhere it to the bottom surface of the soft surface article. When the carpet is installed, the anti-skid component may then be on the bottom of the soft surface article and thus in contact with the foundation upon which the soft surface article will rest. This foundation may be a hard surface or a pad.

[0042] In another of many embodiments that may be envisioned by those of ordinary skill in the art and in possession of this disclosure and the teachings within may be that the anti-skid coating may be applied to the radiation cured backing layer after the radiation-activated backing has been irradiated in any of the manners disclosed herein. The anti-skid layer may be applied with traditional adhesives or by any of the mechanisms disclosed and taught herein.

[0043] If the radiation-activated formulation is applied as a powder, particles, or granules those of ordinary skill in the art will understand that they may fall into or be maneuvered further into the yarn strands to facilitate better tuft binding via embedding prior to going into the liquid, molten, or pre-gelled state and being cured or set with the radiation. Methods of introducing the powder, particles, or granules further into the yarn strands may include, without limitation, mechanical shaking, force blowing, vortex blowing, pressing with a roller, calendaring, needling, arching or otherwise deforming the backing to expose more surface area, and other mechanisms known to those ordinarily skilled in the art.

[0044] In a preferred embodiment, a focused form of energy may be used to activate an energy-activated adhesive. For example, an energy-activated adhesive may be spread across the back of the primary backing prior to tufting, and then pile yarn tufted through it. At a later time, a focused form of energy may be applied at locations on the back of the tufted primary backing to activate the energy-activated adhesive. In one embodiment, this may be through the use of a laser or maser, which would only activate the energy-activated adhesive at locations where the backstitches are exposed on the back of the primary backing. Alternatively, if it is found that adhering the entire length of a backstitch to the back of the primary backing is not required to provide required tuft bind strength, then only a portion of each backstitch may receive the activating energy from the focused form of energy, e.g., the laser, maser, or any other guided energy beam.

[0045] In some embodiments, a maser may be preferred over a laser, or any other source of guided energy beam. In some embodiments, the power from a laser may disrupt or degrade the polymers that make up the filaments. This may occur even if the laser is used at a relatively low intensity and for short durations. The effects may include disrupting the backbones of the chains of polymer, or disrupting the orientation or crystallization of the polymer chains. A maser, with a lower delivery of energy than a laser, may require a longer duration to affect the filaments of a backstitch to produce a desired result, but the energy from the maser may not be sufficient to disrupt or degrade the polymer chain, or its orientation or crystallinity. With that being said, there are some embodiments where a laser provides a desirable amount of energy when applied to some polymers to affect desired results. The selection of a maser, a laser, or another guided energy beam source may be decided upon without undue experimentation. In the case where an energy-activated adhesive had been coated on the back of the primary backing and only portions of it activated to adhere the backstitches to the primary backing, there will be a quantity of un-activated energy-activated adhesive still remaining on the back of the primary backing. Rather than leaving this through the remainder of the process and having it become part of the finished product, the un-activated energy-activated adhesive may be reclaimed to be used in the same way on a subsequent soft surface article.

[0046] Several of the many benefits of this technology for the carpet and flooring industry are: a shorter production line; smaller factory footprint; shorter manufacture time; reduced energy consumption cost; cure-on-demand capabilities; elimination, reduction, or control of mold and bacterial growths; and multi-functionality; along with quality improvements.

[0047] In a cure-on-demand process, the radiation-activated formulation may be applied at one time but not irradiated until a later time or step. This is different from applying a water-based dispersion, which would require drying before the griege product was processed any further. The drying process for traditional latex coated products would need to begin almost immediately after applying the water-based adhesive since the continued presence of that much water in the carpet may adversely affect the final product. Using a radiation-activated formulation and processes disclosed herein may extend the shelf-life of raw materials and eliminate mold and bacterial growth which are concerns associated with water-based dispersions used today for the soft surface and similar industries.

[0048] In another embodiment of a cure-on-demand process, the radiation-activated formulation may be a water-based dispersion having the property of being radiation activated. As an illustrative, but not limiting example, water-based polyurethane having reactive acrylate groups may be applied to a griege. This will need to be dried after the application of the formulation, but it can also be cured afterwards by UV or heat depending on whether the formulation comprises thermo-initiators or photoinitiators.

[0049] One of many possible choices of a cure-on-demand adhesive coating for carpet backing is that a product that may be applied as a hot-melt and then cured with radiation, such as a UV light, to a specific desired level of tack and adhesion strength that can be varied based on its exposure to activating radiation.

[0050] Some examples of radiation-activated formulations comprise acrylic based adhesives such as, but not limited to urethane acrylic, polyester acrylic, and epoxy acrylic based adhesives.

[0051] If a desired property of the finished soft surface article is to be very flexible, a radiation curable resin may be applied such that it will be cured to a Shore Hardness of between 45A and 70A. These may have viscosities of between 2,000 mPa»s and 4,000 mPa»s and produce an adhesive with a tensile strength of between 2 MPa and 5 MPa. These may have an elongation at break of between 120% and 180%. In one embodiment, these may be curable with UV radiation, such as UV-A, UV-B, or UV- C radiation.

[0052] On the other hand, if it is desired to be rigid, a resin may be selected that produces a cured adhesive with a Shore Hardness of between 70D and 100D. These may have viscosities of between 10 mPa»s and 800 mPa»s with a tensile strength of between 20 MPa and 70 MPa. These may have a relatively shorter elongation at break of between 7% and 85%. In one embodiment, these may be curable with UV radiation, such as UV-A, UV-B, or UV-C radiation. Preferably UV-A is used for curing the radiation- activated formulation.

[0053] Having shown the desirable properties of the innovative embodiments of radiation- activated formulations disclosed herein, this specification now turns to the desirable properties of embodiments of heat-activated formulations.

[0054] In an illustrative but not limiting embodiment, a radiation-activated formulation may include one or more acrylic or methacrylic components and one or more photoinitiators. Preferably said one or more photo-initiators may include a photo-initiator that reacts to ultraviolet light. In these illustrative embodiments, it is also preferable to use a UV-A LED as the source of the energy. Heat-activated Formulations

[0055] Also, an alternative to applying traditional flexible coatings (such as a water-based dispersion (e.g., a latex) or a hot melt adhesive), heat-activated adhesive formulations, which may also be called heat-reactive formulations, may be applied and cured rapidly with relatively few heating stations at speeds that are comparable to, or faster than, curing or hardening a traditional latex or hot melt adhesive. While traditional latex and hot melt adhesives are well known by those of ordinary skill in the art, other heat-activated formulations may be used in the embodiments disclosed and taught herein. In these embodiments, heat-activated formulations may include adhesives that contain oligomers where an energy, such as but not limited to heat, may activate the oligomers to form polymers that will adhere to yam and backing to secure tufts in place. In these embodiments, heat may be applied to the adhesive through the use of traditional convection means, such as, but not limited to, an oven.

[0056] Similar to the embodiments disclosing radiation-activated formulation, a heat- activated formulation may also act to adhere additional optically transparent backing layers having or not having coloration included. Such optically transparent backings may be applied as a sheet or a powder. A coloration may be produced through adding a colorant, dye, or by any other means known to those of ordinary skill in the art. Configuring the surface roughness or smoothness of such a back coating may also provide better adhesion to any additional backing layers. This also has potential to improve adhesion to the base floor or to provide anti-skid properties to the soft surface article.

[0057] As one of many possible embodiments, the heat-activated formulation may comprise a substance that melts or becomes a flowable fluid when heated at one temperature and then cures as the heat is continually applied. This may be preferable in an embodiment where the heat-activated formulation is applied to the backing. Once applied and the backing is tufted, a first heating of the tufted backing may occur to melt the heat-activated formulation so that it flows and diffuses into the yarn and the backing. Once the heat-activated formulation has flowed or seeped into the yarn and the backing to a desired degree, it may be cured to anchor the yam to the backing so that it passes delamination and tuft pull tests. The curing may occur by ambient and / or forced cooling. In another embodiment, a first application of heat energy may melt the heat-activated formulation. The backstitching of the yam may then be pressed into the molten heat-activated formulation, and then a second heating may be applied to cure the heat-activated formulation.

[0058] As those ordinarily skilled in the art will appreciate, the amount of heat may be precisely applied to produce reproducible results. For example, and without limitation, a step of heating the applied formulation to activate the formulation may be stopped when the formulation has melted and penetrated the fibers and backing to a desirable amount. This desirable amount may be to an extent that the activated formulation has seeped through the pores in the matrix of the backing to coat at least some portion of the matrix without further advancing into the pile. In some situations, it may be desirable to not have any set / cured adhesive in the base of any tufts in the pile, which may produce an uncomfortable feeling on skin such as bare feet when walked across. Similarly, the step of heating the formulation may involve stopping the heat, and / or actively cooling the soft surface article when the heat-activated formulation has cured to a state that has desirable properties such as, but not limited to tack, adhesion, and flexibility.

[0059] The heat-activated formulation may comprise an initiator, such as but not limited to a thermo-initiator. Examples of thermo-initiators include peroxides, such as Benzoyl Peroxide (BPO) and Tert-Butyl Peroxide, as well as such initiators as Azobisisobutyronitrile (AIBN). Benzoyl Peroxide is effective in the polymerization of acrylics at moderate temperatures. Also, Azobisisobutyronitrile (AIBN) has a high stability and efficiency in initiating free radical polymerizations.

[0060] Those of ordinary skill in the art may understand that some types of heat-activated formulations that may be used with the inventions disclosed and taught herein may have a higher efficacy when a thermo-initiator is used within the formulation, or is applied during any of the steps described herein.

[0061] The heat-activated formulation may also include other components to produce a desirable end result. One envisioned embodiment may include an anti-skid component. In this envisioned embodiment, the heat-activated formulation may comprise a component that melts or becomes molten and flowable when heated at a specific temperature; a component that cures when heated at the same or at a higher temperature; and a component that may form an anti-skid layer. The component used to form an anti-skid layer may have a density different from the other components. In this embodiment, the formulation may be applied to the backing of the carpet section while the backing is facing up and the tufts are facing downwards. In this orientation, gravity may be used to apply the formulation.

[0062] To illustrate this embodiment, the formulation may be applied from above the backing so that it falls onto the backing. This may include, but not be limited to spraying the formulation in a powder, granule, paste, or liquid form onto the backing. The process step of heating the formulation may melt the formulation as described elsewhere herein such that the molten formulation seeps and or is wicked further down into the matrix of the backing and, if desired, to some extent further into the matrix of the backing. At the same time, particles of the component that may form the anti-skid layer may have a different density than the other components such that they rise to the top of the molten formulation and becomes exposed on the surface. After the step that melts the formulation is complete, there may be enough of an antiskid component on the top surface of the carpet backing to provide desirable antiskid properties to the soft surface article. The process may be continued by heating the formulation to cure the formulation. Alternatively, the formulation may be cured and set by cooling it, such as by passing it over a cooling roller. This may then set the anti-skid component. When the carpet is installed, the anti-skid component may then be on the bottom of the soft surface segment and thus in contact with the foundation upon which the soft surface article will rest. This foundation may be a hard surface or a pad.

[0063] In another of many embodiments that may be envisioned by those of ordinary skill in the art and in possession of this disclosure and the teachings within may be that the anti-skid coating may be applied to the heat cured backing layer after the heat- activated backing has been heated in any of the manners disclosed herein. The antiskid layer may be applied with traditional adhesives or by any of the mechanisms disclosed and taught herein. If the heat-activated formulation is applied as a powder, particles, or granules those of ordinary skill in the art will understand that they may fall into or be maneuvered further into the yarn strands to facilitate better tuft binding via embedding prior to going into the liquid or molten state and being cured or set with the heat. Methods of introducing the powder, particles, or granules further into the yam strands may include, without limitation, mechanical shaking, force blowing, vortex blowing, pressing with a roller, calendaring, needling, arching or otherwise deforming the backing to expose more surface area, and other mechanisms known to those ordinarily skilled in the art.

[0064] Several of the many benefits of this technology for the carpet and flooring industry are: a shorter production line; smaller factory footprint; shorter manufacture time; reduced energy consumption cost; cure-on-demand capabilities; elimination, reduction, or control of mold and bacterial growths; and multi-functionality; along with quality improvements.

[0065] In an illustrative but not limiting embodiment, a heat-activated formulation may include one or more acrylate reactive diluents and / or methacrylate reactive diluents and / or (meth)acrylamide reactive diluents. In some preferred embodiments, these reactive diluents have a molar mass lower than 800 g / mol, and preferably lower than 500 g / mol, along with one or more photo-initiators.

[0066] As a specific example, reactive diluents may be added to oligomers for reducing the viscosity of the formulation so it may be applied easier. That is, it may be spread more evenly across a griege. The formulation will remain a liquid, having a low viscosity, and it must be cured to become solid. This may happen in steps. For example, dual cure systems may be used if the components of the formulation comprise appropriate reactive groups such as isocyanate groups, hydroxyl groups or amine groups. Such dual cure systems may include a UV-cure, a thermal cure, or other methods to form covalent bonds between molecules.

[0067] Preferably, the one or more acrylate reactive diluents and / or methacrylate reactive diluents and / or (meth)acrylamide reactive diluents have a viscosity measured at 25°C between 160 mPa»s and 40 Pa»s. Such embodiments result in improved processing of the adhesive composition. Preferably, the one or more acrylate reactive diluents and / or methacrylate reactive diluents and / or (meth)acrylamide reactive diluents have an average molar mass higher than 100 g / mol.

[0068] Preferably, the one or more acrylate reactive diluents and / or methacrylate reactive diluents and / or (meth)acrylamide reactive diluents have a maximal vapor pressure less than 0.02 mbar when measured at 20°C. Such embodiments result in improved processing of the adhesive composition.

[0069] In cure-on-demand, the heat-activated formulation may be applied at one time but not heated until a later time or step. This is different from applying a water-based dispersant such as a traditional latex, which would require drying before the griege product was processed any further. The drying process for traditional latex coated products would need to begin almost immediately after applying the water-based adhesive since the continued presence of that much water in the carpet may adversely affect the final product. Using a heat-activated formulation and process disclosed herein may extend the shelf-life of raw materials and eliminate mold and bacterial growth which are concerns associated with water-based dispersions used today for the soft surface and similar industries.

[0070] Some embodiments of a heat-activated formulation may be made of oligomers that polymerize upon the activation of energy with thermo-initiators. Other embodiments of heat-activated formulations may include multi-part adhesives, or resins. One example of a resin that may be used within the scope of the inventions disclosed and taught herein is a water-based polyurethan dispersion having acrylate functionality.

[0071] Examples of a multi-part adhesive are a water-based two-component formulation and an oligomer-reactive diluent formulation. In these illustrative examples, a first component of the formulation may be a dispersion of amine-, hydroxy-, or carboxyl- functional acrylate copolymer or a polyester polyol or a vinyl polymer. The second part may be a hardening agent such as, but not limited to an isocyanate and / or an aziridine component. A specific example of this may be a formulation of a waterbased lacquer consisting of a dispersion of 40% to 90% by weight of an amine, hydroxy, or carboxy functional copolymer or a polyester polyol as a dry matter; 2% to 20% by weight of an aliphatic isocyanate such as Hexamethylene Di-Isocyanate (HDI). This may be applied to the yam or primary backing in the tufting machine, or it may be incorporated into the yarn or primary backing during the manufacture of those articles. The HDI may be applied with an applicator after tufting. Heat applied will then polymerize the water-based lacquer and bond the backstitching to the primary backing.

[0072] Alternatively, a multi-part adhesive may be cured in ambient conditions upon contacting, e.g. through mixing or otherwise, said two or more components. Further alternatively, an adhesive, whether or not a multi-part adhesive, may be cured by exposure to humidity, preferably water or the ambient humidity. Such may for example be the case with polyurethane based adhesives. Such moisture cure adhesives or ambient curing adhesives are a further alternative to the already mentioned radiation-activated and heat-activated formulations.

[0073] Combinations of Radiation-activated and Heat-activated Formulations

[0074] Also encompassed within the inventions disclosed and taught herein are embodiments where a formulation may comprise a substance that melts when irradiated and another substance that cures and sets when heated. Therefore, a first step may be to apply the formulation; the second step may be to irradiate the applied formulation from a radiation source at a frequency that melts or pre-gels the radiation-meltable component; and a third step of heating the applied and melted formulation from a heat source, or in an oven, that cures the formulation. Appropriate melting and / or curing reactions, e.g., at a desired temperature or radiation frequency, may be set by selection of appropriate thermo-initiators and photo-initiators.

[0075] Alternatively, encompassed within the inventions disclosed and taught herein are embodiments where a formulation may comprise a substance that melts when heated and another substance that cures and sets when irradiated. Therefore, a first step may be to apply the formulation; the second step may be to heat the applied formulation from a heat source that melts the heat-meltable component; and a third step of irradiating the applied and melted formulation from a radiation source that cures the formulation.

[0076] In one of several embodiments that may be envisioned by those of skill in the art and in possession of the inventions disclosed and taught herein, the application of focused energy may be used to apply heat and simultaneously activate an energy-activated formulation. For example, an energy-activated formulation may be applied over the back of a primary backing prior to tufting the primary backing with a pile yarn. In one embodiment, the formulation may be activated by heat. A laser or maser may be used to heat the backstitches of the pile yam so that they become molten. The heat from the molten backstitches will then activate the heat-activated formulation. This may have an added advantage that the molten backstitch filaments may seep into and adhere to the primary backing material. A strong bond may then be formed through the combination of melting the backstitches so that some of the molten backstitch material intermingles with and fuses the primary backing material, and engaging the heat-activated adhesive to anchor the backstitch material to the primary backing.

[0077] In this illustrative example, the fusing may be augmented by applying pressure to the backstitching while it is in a molten state, such as by passing the griege through a nip roller. This would forcibly drive the molten portion of the backstitching into the material of the primary backing along with the activated heat-activated adhesive. The heat-activated adhesive positioned between the backstitching and the primary backing will be spread between them as the molten backstitching is driven into the fabric of the primary backing.

[0078] As has been explained, some portion of the heat-activated formulation may remain un-activated after this process. While it may be left un-activated while the griege is processed into a soft surface article, it may also be reclaimed and reapplied. For example, the un-activated formulation may be washed from the griege through the use of a solvent. The wash may then be processed to recover the un-activated formulation, which may then be reapplied in the same manner to another griege. Alternatively, if the formulation is in the form of a powder or granules, the un- activated powder or granules may be shaken and / or vacuumed from the griege to reclaim it and to be reused.

[0079] As may be understood by those of skill in the art, the use of energy to produce desired results is not limited to only a single application of energy. Different types of energy may be applied to achieve any desired results. For example, as was described, a laser or maser may be focused to apply energy along each backstitch to melt it. Alternatively, that laser or maser may be focused to melt only a portion of each backstitch, such as where the yarn enters and exits the primary backing. In this, the melting of the pile yarn in specific locations will provide a first anchoring of each backstitch to the primary backing as has been described previously. Previous to or after that application of that laser or maser, a second laser or maser may be applied, which only heats the energy-activated adhesive at a location or along a stretch of each backstitch between the locations where the pile yarn enters and exits the primary backing. The bonding between the filaments of the pile yam at the locations along each backstitch where the energy-activated adhesive has been activated will provide a second anchoring of the pile yarns to the primary backing.

[0080] The combination of these two anchorings may be sufficient to achieve a required tuft pull strength and may leave some portion of the backstitches loose along the back of the primary backing. This may be more desirable rather than the option of melting the entire length of each backstitch in that a portion of loose filaments of the backstitching may provide a loft from the primary backing that may add to a cushioning effect when the soft surface article is in use.

[0081] The judicious use of the energy-activated formulation for securing the backstitching to the back of the primary backing may aid in making the soft surface article be more recyclable. As a nonlimiting example, if all of the components of the soft surface article are made from the same polymer, such as PET, polyethylene, or polypropylene, and the energy-activated adhesive is the only component that is not the same polymer, then it may be easy to separate the energy-activated adhesive from the remaining polymer. In another way, the amount of the energy-activated adhesive may be of such a small amount that the preponderance of the soft surface article may be treated as being of sufficient quality of the polymer to be recycled as would an article made entirely of that polymer.

[0082] Preferably, the heat required to activate and / or cure a heat-activated formulation is such that the backstitches remain essentially unaffected by the heat. For example, in the case of PET (polyethylene terephthalate) or Nylon yarn, the heat for activation and / or curing is preferably such that the temperature of the backing remains below 200°C, or below 150°C. In the case of polypropylene yam, the heat for activation and / or curing is preferably such that the temperature of the backing remains below 100°C, or below 80°C. It is however not excluded that higher temperatures would be applied. In such case some extent of melting or alteration in the yarn may be expected. Such melting or alteration may per se also lead to an increased adherence of the yarn to the backing.

[0083] Digitally Printing Energy-activated Formulations

[0084] As disclosed, it may be wasteful or produce unwanted properties to the soft surface when a backing is completely coated with an adhesive. Some prior art embodiments have been proposed where a pre-coat is applied to a backing, and dried to some extent, before the backing is tufted, and then a skip coat applied over the backstitching and the pre-coat. Both of these coatings have traditionally been spread over the entirety of the backing.

[0085] To reduce waste and still produce a soft surface article having strength against delamination and tuft withdrawal, Applicant has envisioned embodiments where energy-activated adhesives are placed and / or activated only where the yarn backstitches meet the backing. In one embodiment, the energy-activated adhesives may be placed in specific locations before tufting and activated at those locations after tufting. In another embodiment, the energy-activated adhesives may be applied generally, and only activated in specific locations after tufting. Those of skill in the art and in possession of this disclosure and its teachings will be able to envision other embodiments that are also within the scope of the claimed inventions.

[0086] The embodiments disclosed and taught herein may use any of the energy-activated formulations disclosed herein including, without limitation, radiation-activated formulations, heat-activated formulations, and combinations of those formulations.

[0087] As will be detailed herein, in some embodiments, energy-activated formulations may be printed, or otherwise spatially distributed, on a backing before, or while it is being tufted. In other embodiments, energy-activated formulations may be transferred to the yarn while the yarn is being tufted. In still other embodiments, formulations may be printed or otherwise spatially distributed on said backing, more particularly at least overlappingly with the backstitches, after tufting, i.e., on a greige. In other embodiments, combinations of printing, or otherwise spatially distributing, energy- activated formulations on a backing may be combined with transferring the same or a different energy-activated formulation to a yam while it is being tufted. In still other embodiments, the respective formulation may be applied to said backing, e.g., to substantially or essentially cover said backing, while only portions thereof are being activated in a spatially distributed manner at least overlappingly with said backstitches.

[0088] In the embodiments disclosed and taught herein, several methods of applying energy- activated formulations may be deployed. As disclosed herein, the formulations may be liquid, paste, gel, particulate matter, or solids dispersed in a medium. As such, methods of applying the formulations to the backing and / or to the yarns may be configured to accommodate the nature of the formulation.

[0089] In one nonlimiting example, if the formulation has a suitable viscosity, it may be applied with a rollerball or ballpoint applicator. In another nonlimiting example, a formulation of granules may be blown on or laid on the backing or yam. In other nonlimiting examples, formulations may be applied in any printing manner such as, but not limited to the use of inkjet printing, valve printing, screen printing, or gravure printing.

[0090] Those familiar with the art of applying these and other formulations may envision other application methods without departing from the spirit of the inventions claimed.

[0091] While the embodiments disclosed and taught herein are of yam and a primary backing, those of ordinary skill in the art will understand that the technologies disclosed and taught herein may be applied to other aspects of creating soft surface articles. For example, and without limitation, the technologies disclosed and taught herein may be used to apply a secondary backing over the primary backing and the backstitching of the yarn. Using the energy-activated formulations as disclosed herein would allow energy-activated formulations to be applied or activated spatially at the location of, or on the backstitching, the underside of the primary backing, and a surface of a secondary backing that will be adhered to the underside of the primary backing. This may be used to strengthen the griege product, and / or to further anchor the tufts and to thwart delamination. The use of digital printing of an energy-activated formulation as disclosed herein may be combined with any of the methods of applying the energy to activate the energy-activated formulation as disclosed and taught herein. For example, an energy- activated formulation may be digitally printed onto the back of a primary backing as disclosed herein as a first step. A second step would be to tuft the primary backing with a pile yarn atop and following the digitally printed formulation. The third step would be to activate the digitally printed formulation by radiating, for example by focusing a laser or maser projection, onto either or both of the backstitching and the digitally printed formulation. As described herein, the yam along each backstitch may be melted to activate the formulation, and / or to only activate the formulation. Similarly, a laser or maser, or other guided energy beam, or radiation may be used to melt a portion of each backstitch at points where the pile yarn enters and exits the primary backing, and a generally spread energy may be used to subsequently activate the portions of the energy-activated formulations that underlie the backstitches of the pile yarn between points where it had been melted by the laser, maser, or any other guided energy beam.

[0092] In some embodiments, a frequency, or frequencies, of radiation may be used that interacts with and heats the material of the pile yarn. The efficacy of this may be at a desired level such that the energy applied to the pile yam will heat the sections of yarn that it is applied to within a desirable period of time. For example, if a production line forwards a griege at a known rate and the irradiating station is a known length, then the duration of time that a section of griege will be in the station may be determined. An intensity of the radiation may be determined. That is to say that the application of the radiation for the duration of time will be knowable. It is desirable that the individual locations of each backstitch will reach a desirable state in that duration with that intensity. That is to say that in one embodiment it is desirable to thoroughly melt the backstitching while each backstitch is being irradiated within the irradiation station. It is therefore desirable that this is achievable with the radiation being used at a specified intensity within the duration of time that the backstitching is in the irradiating station.

[0093] However, even with that, an intensity of the radiation may be insufficient to heat the backstitch within the duration. For example, for a specific length of an irradiating station and at a high intensity, the radiation generated may only soften the backstitch. This may be addressed by lengthening the irradiating station or slowing the rate of movement of the griege through the station. However, these solutions may not be desirable for economic reasons.

[0094] This may be addressed by changing the composition of the pile yarn. For example, ingredients may be added to the polymer that makes up the filaments of the yarn so that are highly reactive to a specific wavelength of radiation. As an example, adding metal flakes to a polymer before it is extruded may make the resulting yam easily heatable when irradiated with microwaves, such as with a maser. While it may not be desirable to embed metal in the filaments, other substances may provide a similar effect in that the resulting filaments may be easily heatable when exposed to certain types of radiation.

[0095] In a similar embodiment, topicals that are reactive to guided energy beams may be applied over the backstitches before the backstitches undergo irradiation from the guided energy beams. For example, an energy absorbent compound that is known to absorb energy at a specific wavelength and release it as heat may be applied as a powder over the entire back face of the griege. The guided energy beams may be focused on the backstitches, or on portions of the backstitches, where the energy absorbent compound will absorb the energy from the guided energy beams and heat the filaments of the backstitches. If desirable, the guided energy beams may be applied to melt the backstitches, thus anchoring them to the primary backing as disclosed herein. If the energy absorbent compound has been distributed over the entire back face of the griege, the portions that have not been entrained in the melted filaments may be recovered and reused as disclosed elsewhere herein.

[0096] As disclosed above, the energy absorbent compound may be chemically inert to the filaments and the primary backing. As such, it may act as a catalyst to bring about any changes desired to the filaments of the backstitching more quickly than would otherwise occur without it. However, such does not always need to be the case.

[0097] In some embodiments, an energy absorbent compound may be mixed with an energy- activated formulation an applied in any of the ways disclosed and taught herein. In doing so, an energy-activated formulation may be activated by the heat released when 1 the energy absorbent compound is plied with energy from a guided energy beam or generally from a broad energy supplying source. In these embodiments, the energy- activated formulation may become an adhesive anchoring the filaments of the backstitches to the primary backing, while the portions of the energy absorbing compound may remain unreacted but be entrained within the adhesive.

[0098] Examples of energy absorbent compounds include, but are not limited to, compounds comprising Silicon Carbide (SiC), Aluminum Nitride (AIN), Beryllium Oxide (BeO) Titanium Dioxide (TiO2) and Zirconia (ZrO2). The topicals applied over the backstitches as mentioned above, may comprise or essentially be dispersions of particles of these compounds.

[0099] In some of the embodiments disclosed and taught herein, the yam may be transparent to the energy transmitted from the guided energy beam. In those embodiments, the focused energy from the guided energy beam may be directed towards the backstitches. The energy will pass through the backstitches and will irradiate the energy-activated formulation to activate it so that it anchors the filaments of the yam to the backing. This is a preferred embodiment for using radiation energy to activate the energy-activated formulation. However, if the yam is coated with an energy absorbent compound, then the energy will be transformed to heat on the yarn such that a heat activated formulation may be used.

[0100] In other embodiments, the yam may be opaque to the energy from the guided energy beam. In that embodiment, the energy may be used to heat the yam so that it activates the energy-activated formulation. This is a preferred embodiment for using heat energy to activate the energy -activated formulation.

[0101] In other embodiments, the yarn may be translucent to the energy from the guided energy beam. In this embodiment, the energy-activated formulation may be either radiation activated, heat activated, or a combination of the two. However, if the yam is coated with an energy absorbent compound, then the energy will be transformed to heat on the yarn such that a heat activated formulation may be preferred.

[0102] In an alternate embodiment, the entire griege may be heated through traditional means as it enters the irradiating station, and then lasers, masers, or other guided energy beams be applied to bring specified locations of each backstitch to a desired state. However, rather than using traditional means to heat the entire griege, it may be more advantageous to use masers to provide an initial heating of the backstitches so that they are at a desired temperature, e.g., below a glass transition temperature of the polymer that the yam is made of. After the backstitches are warmed to a desired temperature, a laser or other source of radiation, which may have more power than a maser, may be used to provide energy to activate the energy-activated formulation and / or to melt portions of the backstitches.

[0103] Exemplary Embodiments

[0104] In one embodiment, the invention relates to a section of a primary carpet backing comprising: a woven or nonwoven carpet backing; and an energy-activated adhesive printed on the section of primary carpet backing.

[0105] In one embodiment, the invention relates to a method of tufting a primary carpet backing, consisting of providing a primary carpet backing; and tufting the primary carpet backing with a yarn; wherein the primary carpet backing comprises an energy- activated adhesive printed thereupon.

[0106] In one embodiment, the invention relates to a method of tufting a primary carpet backing, consisting of providing a primary carpet backing; providing a yam; applying a dollop of energy-activated formulation to a segment of the yam while it is being tufted; and tufting the yam through the primary carpet backing; wherein the dollop of energy-activated formulation is laid between subsequent tufts on the backstitching as the primary carpet backing is advanced in a tufting machine.

[0107] In one embodiment, the invention relates to a soft surface article, wherein said soft surface article is a carpet, a carpet tile or a mg, wherein said soft surface article comprises: a main surface formed by piles of yam; a primary carpet backing, wherein said primary backing is provided with said piles, wherein the side of said primary carpet backing opposite said main surface comprises backstitches of said yam; a spatially distributed adhesive applied to said primary carpet backing at said side thereof opposite said main surface, wherein said spatially distributed adhesive is at least applied over a plurality of said backstitches.

[0108] In one embodiment, the invention relates to the section of primary carpet backing of any preceding first, second, or fourth independent aspects of the invention, wherein the energy-activated adhesive or the energy-activated formulation comprises a radiation-activated formulation, a heat-activated formulation, or a combination of a radiation-activated formulation and a heat-activated formulation.

[0109] In one embodiment, the invention relates to a method of applying an energy-activated formulation to a section of a primary carpet backing comprising: providing a woven or nonwoven primary carpet backing; providing an energy-activated formulation; providing a yam; printing the energy-activated formulation on the primary carpet backing in a tufting machine; wherein: the energy-activated formulation is selected from a group consisting of a radiation-activated formulation, a heat-activated formulation, or a combination thereof; and the energy-activated formulation is printed in a plurality of lines where a row of backstitches of the yarn are configured to be laid during a tufting operation of the primary carpet backing.

[0110] In one embodiment, the invention relates to a method of tufting a primary carpet backing, comprising: providing a primary carpet backing comprising a front side and a back side; providing a yarn; providing a tufting machine; applying a dollop of energy-activated formulation to a segment of the yarn while it is being tufted in the tufting machine; and tufting the yarn through the primary carpet backing; wherein the dollop of energy-activated formulation is configured to be laid between subsequent tufts on a backstitch portion of the yarn as the primary carpet backing is advanced in the tufting machine.

[0111] In one embodiment, the invention relates to a soft surface article, wherein the soft surface article is a carpet, a carpet tile or a rug, comprising: a main surface defined by a pile of yarn; a primary carpet backing, wherein a first side of the primary backing is provided with the pile of yam, and wherein a second side of the primary carpet backing is opposite the first side and comprises backstitches of the yarn; a spatially distributed adhesive applied to the primary carpet backing at the second side, wherein the spatially distributed adhesive is at least applied between each backstitch of a plurality of backstitches and the second side of the primary carpet backing.

[0112] The embodiments stated herein are not mutually exclusive but may be combined with each other. Further to this, in the embodiments disclosed and in the embodiments that will be understood by those of ordinary skill in the art that are within the scope of the claims, have dependent aspects. For example:

[0113] - In the embodiments where an energy-activated adhesive is printed on a primary carpet backing, the energy-activated adhesive may be printed onto the primary carpet backing before the primary carpet backing is loaded into a tufting machine, or the energy-activated adhesive may be printed onto the primary carpet backing within the tufting machine.

[0114] - In the embodiments, the energy-activated adhesive is selected from a group consisting of a radiation-activated formulation, a heat-activated formulation, or a combination thereof.

[0115] - In the embodiments, the energy-activated adhesive becomes molten or pre-gels when exposed to a source of energy.

[0116] - In the embodiments, the energy-activated adhesive becomes flowable when exposed to a source of energy.

[0117] - In the embodiments, the energy-activated adhesive is cured when exposed to a source of energy.

[0118] - In the embodiments, the source of energy is selected from the group consisting of a source of radiation, a source of heat, or a combination thereof.

[0119] - In the embodiments, the source of radiation is selected from the group consisting of ultraviolet radiation, infrared radiation, electron beam radiation, visible light, or combinations thereof.

[0120] - In the embodiments, the printed energy-activated adhesive is printed along a series of lines across the width of the primary carpet backing.

[0121] - In the embodiments, the series of lines across the width of the primary carpet backing is discontiguous along the length of the primary carpet backing. - In the embodiments, the series of lines of energy-activated adhesive will align with the placement of the backstitches of yarn when the section of primary carpet backing is tufted.

[0122] - In the embodiments, an energy-activated formulation is applied over a backstitching of the tufted primary carpet backing.

[0123] - In the embodiments, an energy-activated formulation is applied over a backstitching of the tufted primary carpet backing.

[0124] - In the embodiments, the dollop of energy-activated adhesive is sandwiched between the yarn and the primary carpet backing on the back side of the primary carpet backing.

[0125] - In the embodiments, the adhesive is a two-component adhesive.

[0126] - In the embodiments, a first component of said adhesive is comprised in said yam and / or in said primary backing.

[0127] - In the embodiments, only one of the first or second component is spatially distributed.

[0128] - In the embodiments, the adhesive is spatially distributed in a uniform manner.

[0129] - In the embodiments, the adhesive is spatially distributed in a repeating pattern.

[0130] - In the embodiments, the adhesive is spatially distributed in dot wise and / or line wise manner.

[0131] - In the embodiments, the primary backing comprises a woven or non-woven textile.

[0132] - In the embodiments, the radiation-activated formulation comprises a photoinitiator.

[0133] - In the embodiments, the heat-activated formulation further comprises a thermoinitiator.

[0134] Descriptions of the inventions will be defined in the appended independent claims, while preferred embodiments are defined in the dependent claims. In a first independent aspect, the invention relates to a section of a primary carpet backing comprising: a woven or nonwoven primary carpet backing; and an energy- activated formulation printed on the section of primary carpet backing.

[0135] In a second independent aspect, the invention relates to a section of a primary carpet backing comprising: a woven or nonwoven primary carpet backing; and a formulation that can be activated by energy discreetly deposited on the section of primary carpet backing.

[0136] In a third independent aspect, the invention relates to a method of tufting a primary carpet backing, consisting of: providing a primary carpet backing; and tufting the primary carpet backing with a yam; wherein the primary carpet backing comprises an energy-activated formulation printed thereupon.

[0137] In a fourth independent aspect, the invention relates to a method of tufting a primary carpet backing, consisting of: providing a primary carpet backing; providing a yarn; applying an amount or a dollop of energy-activated formulation to a segment of the yarn while it is being tufted; and tufting the yarn through the primary carpet backing; wherein the dollop of energy -activated formulation is laid between subsequent tufts on a backstitch as the primary carpet backing is advanced in a tufting machine.

[0138] In a fifth independent aspect, the invention relates to a soft surface article, wherein said soft surface article is a carpet, a carpet tile or a rug, wherein said soft surface article comprises: a main surface formed by piles of yarn; a primary carpet backing, wherein said primary backing is provided with said piles, wherein the side of said primary carpet backing opposite said main surface comprises backstitches of said yarn; a spatially distributed adhesive applied to said primary carpet backing at said side thereof opposite said main surface, wherein said spatially distributed adhesive is at least applied over a plurality of said backstitches.

[0139] In a sixth aspect, the invention relates to the section of primary carpet backing wherein the energy-activated formulation comprises a radiation-activated formulation, a heat-activated formulation, or a combination of a radiation-activated formulation and a heat-activated formulation. In a seventh independent aspect, the invention relates to a method of applying an energy-activated formulation to a section of a primary carpet backing comprising: providing a woven or nonwoven primary carpet backing; providing an energy- activated formulation; providing a yarn; printing the energy-activated formulation on the primary carpet backing in a tufting machine; wherein: the energy-activated formulation is selected from a group consisting of a radiation-activated formulation, a heat-activated formulation, or a combination thereof; and the energy-activated formulation is printed in a plurality of lines where a row of backstitches of the yam are configured to be laid during a tufting operation of the primary carpet backing.

[0140] In an eighth independent aspect, the invention relates to a method of tufting a primary carpet backing, comprising: providing a primary carpet backing comprising a front side and a back side; providing a yam; providing a tufting machine; applying an amount or a dollop of energy -activated formulation to a segment of the yarn while it is being tufted in the tufting machine; and tufting the yam through the primary carpet backing; wherein the dollop of energy-activated formulation is configured to be laid between subsequent tufts on a backstitch portion of the yam as the primary carpet backing is advanced in the tufting machine.

[0141] In a ninth independent aspect, the invention relates to a soft surface article, wherein the soft surface article is a carpet, a carpet tile or a mg, comprising: a main surface defined by a pile of yam; a primary carpet backing, wherein a first side of the primary backing is provided with the pile of yarn, and wherein a second side of the primary carpet backing is opposite the first side and comprises backstitches of the yarn; a spatially distributed adhesive applied to the primary carpet backing at the second side, wherein the spatially distributed adhesive is at least applied between each backstitch of a plurality of backstitches and the second side of the primary carpet backing.

[0142] In a tenth independent aspect, the invention relates to a method of anchoring a yarn to a primary backing, comprising: providing the primary backing; providing the yam; distributing an energy-activated formulation onto a first face the primary carpet backing; tufting the yarn into the primary backing, wherein a plurality of pile loops are formed on a second face of the primary backing, and a plurality of backstitches are formed on the first face of the primary backing; and focusing a guided energy beam towards at least one backstitch of the plurality of backstitches to activate the energy-activated formulation.

[0143] In an eleventh independent aspect, the invention relates to a method of tufting a primary carpet backing, comprising: providing a primary carpet backing comprising a front side and a back side; providing a yarn; providing a tufting machine; painting an amount or a dab of energy -activated formulation onto a segment of the yam while it is being tufted in the tufting machine; tufting the yam through the primary carpet backing; wherein the amount or the dab of energy-activated formulation is configured to be laid between subsequent tufts on a backstitch portion of the yarn as the primary carpet backing is advanced in the tufting machine; and activating the amount or the dab of energy-activated formulation by applying energy from a guided energy beam.

[0144] In a twelfth independent aspect, the invention relates to a soft surface article, wherein the soft surface article is a carpet, a carpet tile or a mg, comprising: a main surface defined by a pile of yam; a primary carpet backing, wherein a first side of the primary backing is provided with the pile of yarn, and wherein a second side of the primary carpet backing is opposite the first side and comprises backstitches of the yarn; a spatially distributed adhesive applied to the primary carpet backing at the second side, wherein the spatially distributed adhesive is at least applied between each backstitch of a plurality of backstitches and the second side of the primary carpet backing.

[0145] In a thirteenth independent aspect, the invention relates to a method of tufting a primary carpet backing, consisting of: providing a primary carpet backing; and tufting the primary carpet backing with a yam; wherein the primary carpet backing comprises an energy-activated formulated applied thereupon.

[0146] Where mention is made of a dollop or dab, this is preferably a volume in a range of 0.01 to 1,000 microliter, or preferably in a range of 1 to 100 microliter. A spatially distributed application or print thereof can for example be achieved by means of valve jet printing. Preferably, the amount of energy-activated formulation applied to a segment of a yarn is in the range of 0.05 to 500 microliter per mm length of said segment. Preferably the piles formed by the yam, i.e., at the first side of the primary backing opposite the second side having the backstitches, is essentially free from said formulation.

[0147] Throughout this specification, an energy-activated formulation will include a formulation that is, or is to be, activated by energy. As a non-limiting example, a formulation that is activated by energy may comprise an acrylate oligomer (thus comprising reactive acrylate groups) and a photo-initiator. This formulation is preferably liquid so that it may be applied by a printing method during tufting or after tufting. At a later time, UV radiation may be applied. Under the irradiation of UV radiation, the photo-initiator will split, and will initiate addition reactions of the acrylate groups of the oligomer, increasing the viscosity of the liquid formulation at first by forming larger molecules, and creating solid matter (if the initial formulation comprises sufficient acrylate groups and a sufficient amount of photo-initiator). The solid acts as a binder to anchor the backstitches to the primary backing. Thus, the formulation (comprising the oligomer and the photo-initiator) is an energy-activated formulation, since it can be activated by means of energy.

[0148] In the above non-limiting example, and in general, preferably a solid is obtained as a result of activating the energy -activated formulation by means of energy, for example by means of radiation and / or heat. Alternatively, the activation by means of energy may result in an increase of the viscosity, for example an increase at least to 110%, or at least to 200%, of the initial viscosity, of the energy-activated formulation, as expressed in mPas.

[0149] Viscosities mentioned in the present disclosure may be measured either in accordance with ASTM D445-24, alternatively ASTM D4287-00(2023), with ISO 3104-2023 (procedure A or B), alternatively ISO 2884-1-2024. Unless mentioned otherwise herein, the viscosity is measured at 25°C. BRIEF DESCRIPTION OF THE DRAWINGS

[0150] With the intention of better showing the characteristics of the invention, herein after, as an example without any limitative character, some preferred embodiments are described, with reference to the accompanying drawings, wherein:

[0151] Figure 1 illustrates a prior art soft surface section.

[0152] Figure 2 illustrates a soft surface section where yarns have been tufted into a backing.

[0153] Figure 3 illustrates a soft surface section where a radiation-activated formulation has been applied.

[0154] Figure 4 illustrates a soft surface section where a radiation-activated formulation has been cured.

[0155] Figure 5 illustrates tufting a primary backing that has adhesive printed thereupon.

[0156] Figure 6 illustrates tufting a primary backing where the adhesive is being printed upon the primary backing before tufting.

[0157] Figure 7 illustrates printing an adhesive on a backing while it is being tufted.

[0158] Figure 8 illustrates the application of an adhesive on yarn while a primary backing is being tufted.

[0159] Figure 8A is an enlarged view of a portion of Figure 8.

[0160] DETAILED DESCRIPTION

[0161] With the types of energy-activated formulations disclosed herein, attention will be turned to the methods and processes of application of the energy-activated formulations and methods and processes of activating the energy-activated formulations to produce soft surface articles. Applying Energy-activated Formulations

[0162] Figure 1 illustrates a prior art section 102 of a carpet 100. In ways that are known to those of ordinary skill in the art, yam or other fibers may be tufted into a backing 104. The backing 104 may be considered to be a substrate of a woven or nonwoven nature.

[0163] A yam or yams used to tuft the backing 104 may be prepared in ways that are known to those of ordinary skill in the art.

[0164] In some prior art processing methods, the backstitching of the tufted yarns may be secured to the backing 104 through the addition of water-based adhesives or traditional water-based latexes of adhesive polymers. These adhesives or traditional latexes must be dried for the adhesive to secure the backstitching to the backing 104. In some embodiments, a secondary backing may be secured to sandwich the backstitching between the primary backing 104 and the secondary backing.

[0165] Figure 1 illustrates a section 102 of the carpet 100 as having been treated with a traditional adhesive latex that has been dried onto the substrate. The water from the water-based adhesive must be removed for the traditional adhesive latex to set and secure the fibers to the primary backing. Evaporating the excess water from the water-based adhesive takes a significant amount of energy. This energy has usually been applied with heated air blowing across the water-based adhesive, which is usually done in stages by passing the substrate and water-based-coated backing through multiple ovens while the griege product is stretched on a tenter line.

[0166] The yarn that is tufted through the primary backing forms backstitches on the backing 104 and loops 106 on the front side of the backing.

[0167] One of many embodiments of the inventions disclosed and taught herein is a method of manufacturing a soft surface article comprising the steps of: providing a primary backing woven with a plurality of tufts; distributing an energy-activated formulation onto the primary backing and onto at least a portion of the plurality of tufts; providing at least one source of heat or radiation; and using the at least one source of heat or radiation to at least partially set the energy-activated formulation. Figures 2-4 generally show the application and use of an energy-activated formulation to anchor pile yam backstitches to a primary backing and then activate the formulation such that it becomes an energy-activated adhesive.

[0168] In the inventions disclosed and taught herein, an adhesive may be applied to a backing 208 that may be set in place and cured through the application of energy. In one of many ways that will be known to those in possession of the disclosures and teachings contained herein, the energy-activated adhesive may be set in place over the entirety of the backing 208 and cured by providing energy to the energy-activated adhesive. As has been disclosed herein, the energy-activated formulation may be applied to the backing 208 where the formulation has a radiation-activated formulation, a heat-activated formulation, or a combination of radiation- and heat- activated formulation. Alternatively, the formulation may be ambient cured, or moisture cured. Also as disclosed herein, a combination of radiation- and heatformulations may be applied together, or in a sequence of applications. Also, as disclosed herein, a combination of a radiation- and heat-activated formulation may be exposed to heat first with radiation second, radiation first and heat second, or heat and radiation applied together. Also, after the application of heat, the article may be cooled.

[0169] Figure 2 illustrates that for many carpet manufacturing processes, the back or underside of the backing layer 208 is placed face-up so that materials may be applied to that layer from above with the aid of gravity. This means that during the manufacturing process, the tufts will be formed face-down. Once the manufacturing of the soft surface article is complete, the soft surface article will be installed with the tufts facing the direction of use. This usually means that on a carpet, the tufts will be upwards so they may be walked upon. Unless otherwise stated herein, this disclosure will use the convention that the soft surface article will be processed with a section 204 of the backing 208 to be tufted will be facing substantially upwards such that the backstitching will be on the top and the tufts facing substantially downwards.

[0170] In a simple, but non-limiting example of the inventions disclosed and taught herein, an energy-activated formulation may be applied to a section 204 of the backing 208 of a soft surface article 200. The radiation-activated formulation may be in a powder, particle, or granular form (or combinations of those) and dispersed evenly across a section 204. In one way, this may be applied across an entire segment of carpet at one time. In another way, the powder, particles, and / or granules may be applied as the carpet is unwound from a roller as it is being processed. In those, and many other ways known to those of ordinary skill in the art, the powder, particle, granule, or combination may be applied consistently across the back surface of the section 204.

[0171] Figure 3 illustrates that the section 304 of the backing 308 has been tufted and that the backstitches 310 are exposed on the back of the backing 308.

[0172] Figure 4illustrates that the section 404 is being exposed to an energy source 414 that will cure the energy-activated formulation to anchor the backstitches 412 to the backing 408 within the section 404.

[0173] In embodiments other than the formulation comprising a powder, particles, or granules, the formulation may be a slurry, a liquid, a hot melt, or a film, or any other substance that may be applied to a carpet backing as would be known to those of ordinary skill in the art.

[0174] If it is desired to spread a formulation over the entire primary backing, the formulation may be applied by the process of using a roll-coater, kiss-coater, a sprayer for liquids, a sprayer or duster for powders, particles, granules, and their mixtures, or in other ways known to those of skill in the art. Also, the formulation may be laid onto or poured onto the substrate and spread to equally distribute the formulation. The substrate may include, but not be limited to, the type of the substrate in that it may be jute, a woven or nonwoven matrix, a needle pressed fabric, or any other type of backing known to those of ordinary skill in the art. The formulation in its different media (powder, hot melt, etc.) may coat the substrate in different ways. Distributing the formulation across the substrate in a manner best suited for a resultant adhesion and / or tack after the formulation is cured or set may be done across the entirety of the primary backing. Alternatively, it may be done only on selected areas of the primary backing. For example, an embodiment may include selectively applying an energy-activated formulation to soft-surface articles that will be processed and cut apart to form carpet tiles. The energy-activated formulation may be applied to areas that will subsequently become edges of the carpet tiles and need not be applied to portions that will not become carpet tiles. In that case, the energy- activated formulation on the portions that will not become carpet tiles may remain un-activated and may be recovered for reuse.

[0175] In an exemplary embodiment, the formulation may be applied in the form of a hot melt. Without further processing, the hot melt may just lay atop the substrate and not necessarily properly adhere to the backing and / or the fibers. Similarly, if the formulation is applied as a powder, it may only settle onto the surface and not necessarily properly adhere the fibers to the backing. One way to address this may be through mechanical means. A powder (or particles or granules, or their combination) on a surface may be shaken or vibrated so that it settles further into the matrix and the fibers. The hot melt may be pressed into the fibers and the backing by rollers or other pressing means. Either type of formulation may be forced into the substrate through the application of blowers or jets of air or any other gas.

[0176] Additionally, if the formulation is meltable under the exposure to energy, then the formulation may be exposed in such a way as to melt or partially melt the formulation so that in a molten state it permeates into the substrate. The property of flowing, seeping, or oozing into the crevasses and interstitial voids of the fibers and between the fibers and the pores of the matrix of the backing may be a natural property of the formulation. Conversely, the natural property of the formulation may be that it flows too much when exposed to energy such that it may be preferable to slow the flowability of the formulation when it is in a molten state, especially if it has a low viscosity. Alternatively, it may be that the formulation does not flow to a satisfactory degree. To that end, the flow property of the formulation may be enhanced, augmented, or deprecated by flow enhancers, viscosity reducers or increasers, or other additives that may be added to the formulation to achieve a desired amount of flow during an initial exposure to energy to disperse itself into the spaces between the fibers and the backing.

[0177] An initial exposure to an energy source may be a short exposure to an energy source to transform the formulation on the backing to a molten state. That is to say that the formulation may be irradiated or heated for a short time to turn the formulation from its initial state into a molten state, or any less viscous state, to allow it to flow into interstitial voids to a desirable extent. The amount that the molten formulation flows into the interstitial spaces may be further controlled through temperature or other heat exchange methods. One of many exemplary methods of this type of control may be to control the temperature of the substrate and its ambient environment. That is to say that the substrate may enter a chamber with a controlled temperature and / or humidity wherein the applied formulation is irradiated or exposed to another heat source to produce a molten formulation where it would be known that the irradiated or heated molten formulation will cool at a certain rate within the chamber such that the molten formulation will flow for an extent that will only pass into the substrate for a known amount but will not pass through the matrix and into the tuft. In this it may be desirable that any adhesive not be allowed to enter into the tuft as it may produce an undesirable feeling or sound for anyone coming in contact with the tuft, such as the sole of a foot or shoe walking upon the finished and installed carpet, carpet tile, mat, or rug.

[0178] Alternatively, the initial exposure to energy of the formulation may make the formulation flow into the interstitial voids, which would be stopped by changing at least one environmental condition, such as the temperature. In one exemplary embodiment, this may be accomplished by blowing cold air across the molten formulation at a certain point after it had been exposed to energy. In another exemplary embodiment, this may be accomplished by moving the griege product across a roller cooled to a temperature that would slow the flow of the molten formulation. In another embodiment, if the tufts and the backing are transparent or translucent to the activating radiation, the activating radiation may be applied from the tuft side of the substrate. The radiation may then be used to cure the energy- activated formulation from the tuft side of the substrate while the energy-activated formulation remains molten and perhaps is still flowing on the backing side of the backing.

[0179] In another embodiment, the formulation may be exposed to an energy source for a duration to melt the formulation and cure it. In this embodiment, the energy may at first melt the formulation such that it penetrates the interstitial voids of the backing and also starts the curing process. The continued exposure to energy of the formulation-containing backing would thereby cure the formulation to a point where it had penetrated the interstitial voids of the fibers and seeped into the backing matrix to a desirable amount. In this exemplary embodiment, the energy exposure of the formulation would be of such an intensity so that it could be timed to stop at a point when the molten formulation had penetrated the interstitial voids and into the matrix to a desirable depth and be cured, or partially cured at that point such that it would no longer flow. In this exemplary embodiment, the formulation would be set, or cured, at a desirable point wherein the substrate with the energy-activated formulation would have a desired tack, adhesion, and flexibility.

[0180] In any of these embodiments, an initiator may be utilized. In one of many exemplary embodiments, a photo-initiator, or multiple photo-initiators may be mixed with the radiation-activated formulation prior to the application of the radiation-activated formulation to the carpet backing. Alternatively, a photo-initiator(s) may be applied before or after the application of the radiation-activated formulation. In the cases where a photo-initiator produces gases during irradiation, the gases may be incorporated into the finished product, or they may be removed through such means that include, but are not limited to the use of gas evacuation methods. Similarly for heat-activated formulations where a thermo-initiator may start the reaction to turn oligomers into polymers.

[0181] In any of these embodiments, the flexibility of the finished soft surface article may be configured. That is to say that the formulation may be cured only to an extent desired to allow the finished product to still be rolled without cracking or plastically deforming the cured formulation. The formulation itself can also be tailored to deliver the cured adhesive as one in which the elastomeric properties it delivers are designed to be optimal for the application and allow for the rolling of the soft surface article but also such that the adhesive can relax back to its pre-rolled state in a short time period suitable to allow flattening of the carpet when it is installed.

[0182] In alternative embodiments, it may be desirable to produce a product that is stiff and inflexible. Such may be the case for a carpet tile, which is expected to lay flat on the substrate with no tenting or curling. This may be achieved by applying a formulation that will produce a stiffness to the article when it is cured. Additionally, a secondary backing and / or a pad or underlay may be applied if desired.

[0183] In another of many exemplary embodiments that may be understood by those of ordinary skill in the art and in possession of the disclosures and teachings contained herein, the backing including the formulation may be subject to a first source of energy to melt the formulation such that it flows to a desired depth in the substrate, and then be subject to a second source of energy to stop the flow and to cure the formulation to a desired tack and adhesion. In this exemplary, and non-limiting embodiment, the first source of energy may be radiation in the infrared bandwidth and the second source of energy may be radiation in the ultraviolet bandwidth. Alternatively, both sources of energy may be either infrared or ultraviolet. Additionally, visible light may be used to either melt the formulation and / or cure the formulation, or visible light may be combined with the infrared and / or ultraviolet radiation. Similarly, any type of radiation may be combined with heat to activate an energy-activated formulation to melt in one step and to cure in another.

[0184] In another exemplary embodiment, the energy-activated formulation does not need to be cured to a desired tack and adhesion during one exposure to the energy source. The energy-activated formulation may be partially cured during a first exposure, and then may be cured to a desired tack, adhesion, and flexibility during a second exposure to the energy. Various processes may be performed between the first and second exposures. As those of ordinary skill in the art and in possession of the inventions and teachings in this disclosure may be aware, other exemplary embodiments may have more steps of radiation exposure.

[0185] In one non-limiting embodiment, after a first exposure to an energy source, a first application of an energy-activated formulation may be set to a degree such that additional material may be added to it. This additional material may comprise an antimicrobial substance, a non-microbial harboring substance, an elastomer, a plasticizer, a thickener, and a filler. In some cases, it may be desirable that the filler be transparent or translucent to the radiation being used to cure the radiation- activated formulation. Also, in some cases, the filler may be within a material layer, such as a secondary backing or a pad. In this exemplary embodiment, a second exposure to energy may then be used to secure the secondary backing or pad material to the first layer of the energy-activated formulation.

[0186] In many cases, it is desirable to keep the resulting carpet flexible and elastic. This may be done by not fully curing the energy-activated formulation, but only curing an exposed surface of it, while the interior of the energy-activated formulation remains in a liquid, semi-liquid, molten, semi-molten, gelled, or pre-gelled state. In that case, a plasticizer may be added to the energy-activated formulation so that the exposed surface will retain some elasticity and flexibility. Similarly, a plasticizer may be added after the energy-activated formulation has been cured to a desirable extent, which may be used to set a final flexibility and tack. That is to say that in an envisioned embodiment, the radiation-activated formulation in the carpet may be cured with radiation to a certain extent, and then a plasticizer may be added to the carpet backing to produce a finalized tack and flexibility.

[0187] In an additional embodiment, a second layer of an energy-activated formulation may be added atop the first layer with an additive, such as but not limited to a filler, between the layers. The second layer of energy-activated formulation may be exposed to an energy source to melt and / or cure the second layer and / or the first layer, thereby securing the additive between the layers.

[0188] In another embodiment, the energy-activated formulation may be applied in several layers, or at different depths across the backing of the carpet. This may be used to provide a pattern of the adhesive across the carpet backing. Similarly, the exposure to energy by the substrate with the energy-activated formulation may be done in an irregular manner to provide wrinkles in the form of embossing and / or indentations, patterns, or combinations of all of them across the adhesive backing.

[0189] In a similar embodiment, an anti-slip layer may be applied over a layer of energy- activated formulation such that exposing the energy-activated formulation to an energy source will secure the anti-slip layer to the bottom of the carpet section.

[0190] As noted herein, the energy source does not need to be broad, but may be focused to provide very precise and localized activation of the energy-activated formulation (or formulations) at specific points. With this, the use of a focused energy source may not activate all of the energy-activated formulation that had been applied to the primary backing. In that case, the un-activated energy-activated formulation may be recovered and used in subsequent products.

[0191] Digitally Printing Energy-activated Formulations

[0192] Applicant’s inventions disclosed and taught herein are not limited to spreading an energy-activated formulation across the entirety of a primary backing to be made into a soft surface article.

[0193] In an envisioned embodiment, an energy-activated formulation may be printed onto a primary backing before it is tufted. The energy-activated formulation may be printed onto the primary backing in lines at locations where the backstitches of the yarn will lay over the lines after the primary backing is tufted. After the primary backing is tufted, with the backstitching laying atop the printed energy-activated formulation, the griege product may be exposed to an energy source to anchor the backstitches to the primary backing by melting, gelling, and / or curing the energy- activated adhesive.

[0194] An embodiment of digitally printing an energy-activated formulation onto a backing and then tufting may be illustrated in Figure 5.

[0195] Needles 520 may be arranged in a needle bar in a tufting machine and loaded with yarn 530. A backing 510 may be loaded into the tufting machine and run in a forward direction as indicated by the arrow 502. In one embodiment common to tufting machines, the backing 510 may be loaded so that the underside of the backing is on top and the face 514 of the backing is on the bottom. The needles 520 will tuft the pile (not shown in this illustration) onto the face 514, where the backstitches 532 will be on the back of the primary backing 510.

[0196] In this illustrative embodiment, the tufting machine may have a sliding needle bar, which will offset the needle bar after each piercing. However, those of ordinary skill in the art and in possession of this disclosure and its teaching will understand that other types of needle bars and tufting machines may be used without departing from the inventions disclosed and claimed herein. In one example, two rows of needle bars may be used. In that situation, the lines of printed energy-activated formulation may still be printed where the backstitches will lay during tufting.

[0197] In this illustrative embodiment, the primary backing 510 has been printed with an energy-activated formulation 540. The layout of the energy-activated formulation 540 is directed to where the backstitches 532 will be laid from the tufting.

[0198] Some energy-activated formulations on primary backings may cause problems when needles are used to tuft yarn through the primary backing and an energy-activated formulation. For example, a needle attempting to tuft a yam through a primary backing that had been covered with a traditional latex may pick up some of the traditional latex when inserting or withdrawing the needle. This may cause the needle to bind in subsequent piercings, or to cause the yam to stick within the needle. To alleviate that, in some embodiments, spaces 550 may be left unprinted. That is to say that the printing of the energy-activated formulation may be discontiguous. That is to say that one set of lines running across the width of the primary backing (as viewed orthogonal to the direction of feed 502) will not be contiguous with previous or subsequent lines. In this illustrative embodiment, the spaces 550 have been left unprinted so that the needles 520 will not contact the energy-activated formulation 540. In other embodiments, where the printed energy-activated formulation does not cause any problems for the needles or yarn while tufting, the printed lines of the energy-activated formulation may be contiguous.

[0199] As may be seen in this exemplary embodiment, the backstitches 532 are laid atop the printed lines of the energy-activated formulation 540 after the needles 520 tuft a row. As is known in the art, tufting may be done near the edges of the primary backing 510, but usually some selvage 512 is left on each side.

[0200] The alignment of the energy-activated formulation 540 and the needles 520 while the primary backing 510 is moving through the tufting machine may be set by means known to those ordinarily skilled in the art of tufting and the operations of tufting machines. That is to say that adjustments of the locations of where the needles will pierce the primary backing may be made by shifting the primary backing to the left or right and by advancing or retarding the forward motion of the primary backing. Those of skill in the art may use timing mechanisms coordinated with strobe lights and high-speed camaras or other means to synchronize the placement of the printed lines of energy-activated adhesive with the placement of the tufting needles.

[0201] In this, and all other embodiments relating to printed energy-activated formulations, the formulation may be softened, melted, pre-gelled, gelled, liquified, and / or cured by the application of energy.

[0202] It is to be known that the exemplary griege product exemplified in this illustrative embodiment that is prepared with any energy-activated formulation disclosed herein may be processed using the methods of applying heat and / or radiation that have also been disclosed herein. For example, in this embodiment and as has been exemplified elsewhere in this disclosure, if the energy-activated formulation 540 comprises a radiation-activated formulation and a heat-activated formulation, the griege product may be exposed to heat immediately after tufting to melt the overall formulation so that it seeps into the primary backing 510 and into the backstitches 532. After the formulation has seeped into the primary backing 510 and the backstitches 532 to a desired degree, the griege product may be removed from the heat source and / or actively cooled. The griege product may also be exposed to a radiation source that will cure and set the radiation-activated formulation.

[0203] While the illustrative embodiment of Figure 5 exemplifies a primary backing 510 that had been printed in advance of loading it into a tufting machine, such does not need to always be the case.

[0204] In this, and all embodiments disclosed herein, the energy-activated formulation may be partially cured before tufting. In the exemplary embodiment of Figure 5, the energy-activated adhesive 540 may be printed on the primary backing 510 and partially cured before being fed into the tufting machine. This may turn the printed energy-activated formulation into a gel so that it seeps into the primary backing. Some energy-activated formulations will first turn into a gel when exposed to a limited amount of energy but will not fully cure. The primary backing with the gelled energy-activated formulation may then be tufted and finally exposed to energy that will cure the energy-activated formulation. In another exemplary embodiment, the energy-activated formulation may be applied within the tufting machine. Figure 6 illustrates one such exemplary embodiment. In this embodiment, the energy-activated formulation may be applied to the primary backing 510 within the tufting machine at any point before the needles 520 tuft the yarn 530. Applicators 660 may be coordinated with the operations of the needle bar to raise, lower, and (if so configured) to slide left and right so that they apply a desirable amount of energy-activated formulation to the primary backing 510 as it is advancing in the tufting machine. As seen in Figure 6, the applicators 660 have drawn lines of energy-activated formulation 550 on the primary backing 510 in locations where the backstitches 532 will lay.

[0205] While the illustrative embodiment of Figure 6 displays one line of applicators 660, such is not a limitation to the inventions disclosed and taught herein. In one embodiment, multiples lines of applicators may be deployed before the line or lines of needles. The rows of applicators may be coordinated with the row or rows of needles for whatever tufting gauge is desired. In this, one set of applicators may be applying a radiation-activated formulation, with another set of applicators applying a heat-activated formulation. It may be desired that one be printed atop the other, or it may be desired that they may be printed side-by-side with a small tolerance. For the former, the backstitches of the yarn may be conjured to lay atop the two energy- activated formulation lines. One or both of the energy-activated formulations may be activated or partially activated before tufting to secure both to the primary backing. After tufting, both may be exposed to a source of energy to melt and / or cure the energy-activated formulations so that the backstitches are anchored to the tufts to the primary backing. For the latter, the backstitches of the yarn may be configured to lay atop the abutment of the two energy-activated formulations. It may be that the yam may be wide enough to lay over both. Alternatively, the backstitches may be laid atop one segment. That may be where one formulation may be partially activated so that it seeps or oozes into the yarn, and then both are later fully or partially cured to fully anchor the yarn to the primary backing.

[0206] In a similar manner, multiple lines of applicators may be configured to apply an energy-activated formulation. In some narrow-gauge tufting machines, or in tufting machines that are configured with multiple rows of needle bars, it may be encumbering to have a single row of applicators. In these situations, multiple rows of applicators may be able to print energy-activated formulations on the primary backing so that all rows of backstitches will be laid atop the printed lines of energy- activated formulation.

[0207] In another embodiment, multiple rows of applicators may be configured to distribute energy-activated formulations where some are side-by-side and others are atop a previously printed energy -activated formulation.

[0208] Figure 7 illustrates another exemplary embodiment of applying energy-activated formulations. In this illustrative embodiment, lines of one type of energy-activated formulation 540 have been applied before the yarn 530 has been tufted into the primary backing 510. In this exemplary embodiment, the needles 520 tuft the yam 530 so that the backstitches 532 are laid atop the lines of energy-activated formulation 540. After tufting, a series of applicators 770 may be configured to extrude dollops 780 of the same, or a different type of energy-activated formulation onto the tufted primary backing 510 at points where the needles 520 pierced the primary backing 510 to form loops.

[0209] While many of the advantages of applying different types of energy-activated formulations have been disclosed and taught herein, a specific embodiment may be described for the illustrative example of Figure 7. The lines of energy-activated formulations 540 may comprise an adhesive that is generally flexible and has a moderate resistance to tuft withdrawal. If it were used by itself, it may not be able to pass a tuft binding test, such as is standardized in ASTM standard D1335-12. However, the dollops of energy-activated formulations 780 may comprise an adhesive that is brittle but exhibits a very strong resistance to tuft withdrawal. If used by itself in making a griege product, it would pass the ASTM standardized test, but would result in an inflexible soft surface article that may exhibit a crunching sound when walked upon. However, when using the two different types of energy-activated formulations in this way, a griege product may be produced having high tuft binding strength and yet still be flexible, without exhibiting any unwanted sounds or feelings.

[0210] In one of many embodiments that may be envisioned by those of ordinary skill in the art and in possession of this disclosure, applicators 770 may be configured to place an energy-activated formulation dollop 780 at the surface of the primary backing 510. Alternatively, the applicators 770 may be configured with a sharpened end so that they inject the dollops 780 into the matrix of the primary backing 510. In another embodiment, the applicators 770 may inject the dollops 780 into the matrix of the primary backing 510 so that some portion of each dollop reaches the top 514 of the primary backing (the side with the pile) and forms a bond between the top 514 of the primary backing and the base of each tuft.

[0211] In some embodiments, the dollops 780 may be individually treated with energy from an energy source, such as a laser, a maser, or any other type of energy beam, whether focused or not. In this, the laser or maser would be able to focus energy directly onto the dollops 780 to provide a final cure to the curable and / or settable components in the dollops 780.

[0212] As has been disclosed and taught throughout this specification, the energy-activated formulations applied to the griege product do not need to be exposed to sources of energy immediately after their application. Various forms of energy may be applied to the griege product to soften and / or melt the formulations, and to cure the formulations. The order of softening, melting, and curing may be configured for each type of energy-activated formulations depending upon the desired outcome.

[0213] While some exemplary embodiments disclosed and taught herein illustrate that energy-activated formulations may be applied to a primary backing before or after tufting, the inventions taught and disclosed herein are not limited to those exemplary embodiments.

[0214] Figure 8 illustrates an embodiment where an energy-activated formulation 840 may be applied to the yam 830 as it is dispensed from the needle 820. In this, an applicator 870 is moved close to the yam 830 after the needle 820 has been withdrawn from the primary backing 810 from forming a loop 816. The applicator 870 dabs some energy- activated formulation 840 onto the side of the yarn 830 that will contact the bottom of the primary backing 810 as a backstitch 832 between loops 816. The applicator 870 may then be backed away from the needle 820 when the needle 820 starts moving downwards to pierce the primary backing 810 to form another loop 816. This may be illustrated to a greater degree in Figure 8A, which is an enlargement of a portion of Figure 8. As may be seen in Figure 8A, once the yarn 830 is painted with some energy-activated formulation 840, it is stitched into the primary backing. The sandwiched energy -activated formulation 842 then lays between the backstitches 832 and the primary backing 810.

[0215] As those familiar with tufting machines will know, some tufting machines have a gate (sometimes known as a looper) that will engage the yam 830 at the bottom of the loop 816 as the needle 820 is withdrawn from the primary backing 810. While a gate will not place any tension on the loop, it will hold the loop in place while the needle 820 is withdrawn. As with the other embodiments disclosed and taught herein, it may be desirable to increase the contact area between the backstitches 832, the energy-activating formulation 840, and the primary backing 810 before melting or curing the energy-activating formulation 840. If this is desired, the tufting line may be configured to press the backstitches 832 to the primary backing 810 by calendaring or any other means known to those ordinarily skilled in the art.

[0216] This is not to say that pressing the backstitching to the primary backing is required. In some embodiments, simply tufting the yam through the primary backing produces sufficient contact between the yam and the backing to ensure satisfactory contact between them.

[0217] When the backstitches 832 are in contact with the primary backing 810 to a satisfactory degree, the energy-activated formulation may be exposed to one or more energy sources.

[0218] In this embodiment, an energy-activated formulation need not be printed on the primary carpet backing before the tufting operation. In some embodiments this may be done, but in other embodiments the tufting may be done without any adhesive preapplied to the primary carpet backing. In some of these embodiments, the dollop of energy-activated formulation may be sufficient to anchor the tuft to the primary carpet backing after the energy-activated formulation has been cured. In other embodiments, the energy-activated formulation may be cured to provide a strong resistance to tuft withdrawal, and another formulation, such as but not limited to a traditional latex, or a hot melt adhesive may be applied over the back side of the tufted primary carpet backing to fully anchor and secure the tufts.

[0219] Applying an energy-activated formulation in this way may lower the overall cost of the produced soft surface article. For example, an energy-activated formulation may be expensive and costly to use in covering the entire back side of a primary carpet backing to fully secure all of the tufts in place. Similarly, a traditional latex or a hot melt adhesive may be costly to use by itself to secure all of the tufts to the backing. However, using an amount or a dollop of energy-activated formulation at the site of each tuft will be far less expensive than covering the back side of the primary backing. When this is cured, a greatly reduced amount of traditional latex or hot melt adhesive may be applied and set to provide a soft surface article with superior properties of tuft strength and delamination. This soft surface article will have a much lower cost to produce than a soft surface article made with only an energy-activated formulation or made with a traditional latex or hot melt adhesive.

[0220] Similar cost savings may be realized through the use of printing an energy-activated formulation in the locations where the backstitches will be laid since this requires far less energy-activated formulation than to cover an entire backing with the formulation.

[0221] In preferred embodiments, energy-activated formulations may be applied and activated in open atmosphere environments. However, some energy-activated formulations must be applied and activated under neutral gases. This may be performed by enclosing all or part of the tufting machine in an enclosure, or by blowing a neutral gas, such as carbon dioxide or nitrogen, across the portions of the tufting machine.

[0222] Exemplary Embodiments

[0223] The present invention is in no way limited to the herein above-described embodiments. On the contrary many such flexible energy-activated formulations may be devised and applied according to various variations of the inventions disclosed and taught herein, without leaving the scope of the present invention. The following exemplary embodiments illustrate some of the above-described embodiments. Those of ordinary skill in the art will be able to envision other embodiments without leaving the scope of the present invention. They will also be able to understand that combinations of these exemplary embodiments are also within the scope of the present invention.

[0224] Example A

[0225] Distribution of the energy-activated formulation: The energy-activated formulation is distributed evenly over the bottom side of the primary backing in any form (e.g., granules, powder, liquid, slurry, etc.)

[0226] Yarn characteristics: Any yarn may be used.

[0227] Application of energy: Heat may be broadly applied if the energy-activated formulation is a heat-activated formulation. Radiation may be applied if the energy- activated formulation is a radiation-activated formulation.

[0228] Results: The energy applied will activate the energy-activated formulation to anchor the backstitches to the primary backing.

[0229] Example B

[0230] Distribution of the energy-activated formulation: The energy-activated formulation is a radiation-activated formulation and is distributed evenly over the bottom side of the primary backing in any form (e.g., granules, powder, liquid, slurry, etc.)

[0231] Yam characteristics: A yarn that is transparent to the radiation to be used is preferred.

[0232] Application of energy: Radiation is applied in the form of a focused energy beam. The focused energy beam will be focused towards the backstitches.

[0233] Results: The radiation from the focused energy beam will activate the energy- activated formulation in the locations under the backstitches to anchor the backstitches to the primary backing. Un-reacted energy-activated formulation may be recovered from the griege.

[0234] Example C Distribution of the energy-activated formulation: The energy-activated formulation is a heat-activated formulation and is distributed evenly over the bottom side of the primary backing in any form (e.g., granules, powder, liquid, slurry, etc.)

[0235] Yam characteristics: A yarn that is transparent to the radiation to be used is preferred. The yarn is coated with an energy absorbent compound.

[0236] Application of energy: Radiation is applied in the form of a focused energy beam. The focused energy beam will be focused towards the backstitches.

[0237] Results: The radiation from the focused energy beam will heat the backstitches, which will activate the energy-activated formulation in the locations under the backstitches to anchor the backstitches to the primary backing. The heat generated by the energy absorbent compound may also melt the filaments of the yarn so that they flow into the primary backing and further anchor the backstitches to the primary backing. Un-reacted energy-activated formulation may be recovered from the griege.

[0238] Example D

[0239] Distribution of the energy-activated formulation: The energy-activated formulation is a heat-activated formulation and is distributed evenly over the bottom side of the primary backing in any form (e.g., granules, powder, liquid, slurry, etc.)

[0240] Yam characteristics: A yarn that is absorbent of the radiation to be used is preferred. The yarn may optionally be coated with an energy absorbent compound.

[0241] Application of energy: Radiation is applied in the form of a focused energy beam. The focused energy beam will be focused towards the backstitches.

[0242] Results: The radiation from the focused energy beam will heat the backstitches, which will activate the energy-activated formulation in the locations under the backstitches to anchor the backstitches to the primary backing. The heat generated by the energy absorbent compound may also melt the filaments of the yarn so that they flow into the primary backing and further anchor the backstitches to the primary backing. Un-reacted energy-activated formulation may be recovered from the griege.

[0243] Example E Distribution of the energy-activated formulation: The energy-activated formulation is a radiation-activated formulation and is digitally printed on the bottom side of the primary backing in lines where the backstitches will lay after tufting.

[0244] Yam characteristics: A yarn that is transparent to the radiation to be used is preferred.

[0245] Application of energy: Radiation is applied in the form of a focused energy beam. The focused energy beam will be focused towards the backstitches.

[0246] Results: The radiation from the focused energy beam will activate the energy- activated formulation in the locations under the backstitches to anchor the backstitches to the primary backing.

[0247] Example F

[0248] Distribution of the energy-activated formulation: The energy-activated formulation is a heat-activated formulation and is digitally printed on the bottom side of the primary backing in lines where the backstitches will lay after tufting. The heat- activated formulation comprises an energy absorbent compound.

[0249] Yam characteristics: A yarn that is transparent to the radiation to be used is preferred.

[0250] Application of energy: Radiation is applied in the form of a focused energy beam. The focused energy beam will be focused towards the backstitches.

[0251] Results: The radiation from the focused energy beam will heat the energy absorbent compound, which will activate the energy-activated formulation in the locations under the backstitches to anchor the backstitches to the primary backing.

[0252] Example G

[0253] Distribution of the energy-activated formulation: The energy-activated formulation is a heat-activated formulation and is digitally printed on the bottom side of the primary backing in lines where the backstitches will lay after tufting.

[0254] Yam characteristics: A yarn that is transparent to the radiation to be used is preferred. The yarn is coated with an energy absorbent compound.

[0255] Application of energy: Radiation is applied in the form of a focused energy beam. The focused energy beam will be focused towards the backstitches. Results: The radiation from the focused energy beam will heat the energy absorbent compound in the yarn, which will activate the energy-activated formulation in the locations under the backstitches to anchor the backstitches to the primary backing. The heat generated by the energy absorbent compound may also melt the filaments of the yarn so that they flow into the primary backing and further anchor the backstitches to the primary backing.

[0256] Example H

[0257] Distribution of the energy-activated formulation: The energy-activated formulation is a heat-activated formulation and is digitally printed on the bottom side of the primary backing in lines where the backstitches will lay after tufting.

[0258] Yarn characteristics: The yam will be made with filaments that are reactive to radiation such that they heat when exposed to certain types of radiation.

[0259] Application of energy: Radiation is applied in the form of a focused energy beam. The focused energy beam will be focused towards the backstitches.

[0260] Results: The radiation from the focused energy beam will heat the filaments of the yarn, which will activate the energy-activated formulation in the locations under the backstitches to anchor the backstitches to the primary backing. The heat generated by the energy absorbent compound may also melt the filaments of the yarn so that they flow into the primary backing and further anchor the backstitches to the primary backing.

[0261] Example I

[0262] Distribution of the energy-activated formulation: The energy-activated formulation is painted onto the yam as it is being tufted into the primary backing.

[0263] Yarn characteristics: Any yarn may be used.

[0264] Application of energy: Heat may be broadly applied if the energy-activated formulation is a heat-activated formulation. Radiation may be applied if the energy- activated formulation is a radiation-activated formulation.

[0265] Results: The energy applied will activate the energy-activated formulation to anchor the backstitches to the primary backing. Example J

[0266] Distribution of the energy-activated formulation: The energy-activated formulation is a heat-activated formulation and is distributed evenly over the bottom side of the primary backing in any form (e.g., granules, powder, liquid, slurry, etc.)

[0267] Yarn characteristics: Any yarn may be used. An energy absorbent compound is painted onto the yarn as it is being tufted into the primary backing.

[0268] Application of energy: Radiation is applied in the form of a focused energy beam. The focused energy beam will be focused towards the backstitches.

[0269] Results: The radiation from the focused energy beam will heat the energy absorbent compound, which will activate the energy-activated formulation in the locations under the backstitches to anchor the backstitches to the primary backing. The heat generated by the energy absorbent compound may also melt the filaments of the yarn so that they flow into the primary backing and further anchor the backstitches to the primary backing. Un-reacted energy-activated formulation may be recovered from the griege.

[0270] Example K

[0271] Distribution of the energy-activated formulation: The energy-activated formulation is a heat-activated formulation and is distributed evenly over the bottom side of the primary backing in any form (e.g., granules, powder, liquid, slurry, etc.)

[0272] Yarn characteristics: The yam will be made with filaments that are reactive to radiation such that they heat when exposed to certain types of radiation.

[0273] Application of energy: Radiation is applied broadly over the back of the primary backing.

[0274] Results: The radiation will heat the yarn, which will activate the energy-activated formulation in the locations under the backstitches to anchor the backstitches to the primary backing. The heat generated by the yarn may also melt the filaments of the yarn so that they flow into the primary backing and further anchor the backstitches to the primary backing. Un-reacted energy-activated formulation may be recovered from the griege. Example L

[0275] Distribution of the energy-activated formulation: The energy-activated formulation is a heat-activated formulation or a radiation-activated formulation and is distributed as dollops by applicators at points where the needles pierced the primary backing to form loops of yarn.

[0276] Yarn characteristics: Any yarn may be used.

[0277] Application of energy: Heat may be broadly applied if the energy-activated formulation is a heat-activated formulation. Radiation may be applied if the energy- activated formulation is a radiation-activated formulation.

[0278] Results: The energy applied will activate the energy-activated formulation to anchor the backstitches to the primary backing at the locations where the yarn goes through the primary backing.

[0279] Example M

[0280] Distribution of the energy-activated formulation: The energy-activated formulation is a heat-activated formulation and is distributed evenly over the bottom side of the primary backing in any form (e.g., granules, powder, liquid, slurry, etc.) An energy absorbent compound is applied as dollops by applicators at points where the needles pierced the primary backing to form loops of yarn on the upper side of the primary backing.

[0281] Yarn characteristics: Any yarn may be used.

[0282] Application of energy: Radiation is applied in the form of a focused energy beam. The focused energy beam will be focused towards the points where the energy absorbent compound has been applied at points where the yarn has pierced the primary backing to form loops.

[0283] Results: The energy applied will heat the energy absorbent compound to activate the energy-activated formulation to anchor the backstitches to the primary backing at the locations where the yarn goes through the primary backing.

[0284] As noted, combinations of these exemplary embodiments may be used to produce results that are still within the scope of the inventions disclosed and taught herein.

Claims

CLAIMS1. A section of a primary carpet backing comprising: a woven or nonwoven primary carpet backing; and an energy-activated formulation printed on the section of primary carpet backing.

2. The section of primary carpet backing of claim 1, wherein the energy- activated formulation is printed on the primary carpet backing before it is loaded into a tufting machine.

3. The section of primary carpet backing of claim 1, wherein the energy- activated formulation is printed on the primary carpet backing in a tufting machine.

4. The section of primary carpet backing of any preceding claim 1-3, wherein the energy-activated formulation is selected from a group consisting of a radiation- activated formulation, a heat-activated formulation, or a combination thereof.

5. The section of primary carpet backing of any preceding claim 1-4, wherein the energy-activated formulation becomes molten or pre-gels when exposed to a source of energy.

6. The section of primary carpet backing of any preceding claim 1-5, wherein the energy-activated formulation becomes flowable when exposed to a source of energy.

7. The section of primary carpet backing of any preceding claim 1-6, wherein the energy-activated formulation becomes an adhesive when exposed to a source of energy.

8. The section of primary carpet backing of any preceding claim 5-7, wherein the source of energy is selected from the group consisting of a source of radiation, a source of heat, or a combination thereof.

9. The section of primary carpet backing of claim 8, wherein the source of radiation is selected from the group consisting of ultraviolet radiation, infrared radiation, electron beam radiation, visible light, microwave radiation, laser radiation, maser radiation, a guided energy beam, or combinations thereof.

10. The section of primary carpet backing of any preceding claim 1-9, wherein the energy-activated formulation is printed along a series of lines across a width of the primary carpet backing.

11. The section of primary carpet backing of claim 10, wherein at least one line of the series of lines across the width of the primary carpet backing is discontiguous along a length of the primary carpet backing.

12. The section of primary carpet backing of any preceding claim 10-11, wherein at least one line of the series of lines of energy-activated formulation will align with the placement of the backstitches of yarn when the section of primary carpet backing is tufted.

13. The section of primary carpet backing of any preceding claim 1-12, wherein the section of primary carpet backing is tufted with a pile yam.

14. The section of primary carpet backing of claim 13, wherein the pile yarn comprises a polymer and an energy absorbent component that heats when exposed to radiation.

15. The section of primary carpet backing of claim 14, wherein the radiation is from a guided energy beam.

16. The section of primary carpet backing of claim 15, wherein a source of the radiation from the guided energy beam is selected from the group consisting of a laser or a maser.

17. The section of primary carpet backing of any preceding claim 13-16, wherein a portion of the energy-activated formulation remains un-activated on the primary carpet backing.

18. The section of primary carpet backing of claim 17, wherein the energy- activated formulation becomes an adhesive when exposed to a source of energy.

19. The section of primary carpet backing of claim 18, wherein the pile yarn is comprised of filaments and the adhesive anchors a plurality of the filaments to the primary backing.

20. The section of primary carpet backing of claim 19, wherein the tufted section of primary carpet backing is finished as a soft surface article selected from a group consisting of a carpet, a carpet tile, or a rug.

21. A section of a primary carpet backing comprising: a woven or nonwoven primary carpet backing; and a formulation that can be activated by energy discreetly deposited on the section of primary carpet backing.

22. The section of primary carpet backing of claim 21, wherein the energy- activated formulation is discreetly deposited on the primary carpet backing before it is loaded into a tufting machine.

23. The section of primary carpet backing of claim 21, wherein the energy- activated formulation is discreetly deposited on the primary carpet backing in a tufting machine, preferably at the side of the primary carpet backing from which pile yarns are inserted in the primary carpet backing in the tufting machine.

24. The section of primary carpet backing of any preceding claim 21-23, wherein the energy-activated formulation is selected from a group consisting of a radiation- activated formulation, a heat-activated formulation, or a combination thereof.

25. The section of primary carpet backing of any preceding claim 21-24, wherein the energy-activated formulation becomes molten or pre-gels when exposed to a source of energy.

26. The section of primary carpet backing of any preceding claim 21-25, wherein the energy-activated formulation becomes flowable when exposed to a source of energy.

27. The section of primary carpet backing of any preceding claim 21-26, wherein the energy-activated formulation becomes an adhesive when exposed to a source of energy.

28. The section of primary carpet backing of any preceding claim 25-27, wherein the source of energy is selected from the group consisting of a source of radiation, a source of heat, or a combination thereof.

29. The section of primary carpet backing of claim 28, wherein the source of radiation is selected from the group consisting of ultraviolet radiation, infrared radiation, electron beam radiation, visible light, microwave radiation, laser radiation, maser radiation, a guided energy beam, or combinations thereof.

30. The section of primary carpet backing of any preceding claim 21-29, wherein the energy-activated formulation is discreetly deposited along a series of lines across a width of the primary carpet backing.

31. The section of primary carpet backing of claim 30, wherein at least one line of the series of lines across the width of the primary carpet backing is discontiguous along a length of the primary carpet backing.

32. The section of primary carpet backing of any preceding claim 30-31, wherein at least one line of the series of lines of energy-activated formulation aligns with the placement of the backstitches of yarn when the section of primary carpet backing is tufted.

33. The section of primary carpet backing of any preceding claim 21-32, wherein the section of primary carpet backing is tufted with a pile yam.

34. The section of primary carpet backing of claim 33, wherein the pile yam comprises a polymer and an energy absorbent component that heats when exposed to radiation.

35. The section of primary carpet backing of claim 34, wherein the radiation is from a guided energy beam.

36. The section of primary carpet backing of claim 35, wherein a source of the radiation from the guided energy beam is selected from the group consisting of a laser or a maser.

37. The section of primary carpet backing of any preceding claim 33-36, wherein a portion of the energy-activated formulation remains un-activated on the primary carpet backing.

38. The section of primary carpet backing of claim 37, wherein the energy - activated formulation becomes an adhesive when exposed to a source of energy.

39. The section of primary carpet backing of claim 38, wherein the pile yarn is comprised of filaments and the adhesive anchors a plurality of the filaments to the primary backing.

40. The section of primary carpet backing of claim 39, wherein the tufted section of primary carpet backing is finished as a soft surface article selected from a group consisting of a carpet, a carpet tile, or a rug.

41. A method of tufting a primary carpet backing, consisting of: providing a primary carpet backing; and tufting the primary carpet backing with a yam; wherein the primary carpet backing comprises an energy-activated formulation printed thereupon.

42. The method of tufting a primary carpet backing of claim 41, wherein the energy-activated formulation is printed on the primary carpet backing before it is loaded into a tufting machine.

43. The method of tufting a primary carpet backing of claim 41, wherein the energy-activated formulation is printed on the primary carpet backing in a tufting machine.

44. The method of tufting a primary carpet backing of any preceding claim 41-43, wherein the energy-activated formulation is selected from a group consisting of a radiation-activated formulation, a heat-activated formulation, or a combination thereof.

45. The method of tufting a primary carpet backing of any preceding claim 41-44, wherein the energy-activated formulation becomes molten or pre-gels when exposed to a source of energy.

46. The method of tufting a primary carpet backing of any preceding claim 41- 45, wherein the energy-activated formulation becomes flowable when exposed to a source of energy.

47. The method of tufting a primary carpet backing of any preceding claim 41-46, wherein the energy-activated formulation becomes an adhesive when exposed to a source of energy.

48. The method of tufting a primary carpet backing of any preceding claim 41-47, wherein the energy-activated formulation is exposed to a source of energy after tufting the primary carpet backing with the yam.

49. The method of tufting a primary carpet backing of any preceding claim 45-48, wherein the source of energy is selected from the group consisting of a source of radiation, a source of heat, or a combination thereof.

50. The method of tufting a primary carpet backing of claim 49, wherein the source of radiation is selected from the group consisting of ultraviolet radiation, infrared radiation, electron beam radiation, visible light, microwave radiation, laser radiation, maser radiation, a guided energy beam, or combinations thereof.

51. The method of tufting a primary carpet backing of any preceding claim 41- 50, wherein the printed energy-activated adhesive is printed along a series of lines across the width of the primary carpet backing.

52. The method of tufting a primary carpet backing of claim 51, wherein at least one line of the series of lines across the width of the primary carpet backing is discontiguous along a length of the primary carpet backing.

53. The method of tufting a primary carpet backing of any preceding claim 51- 52, wherein at least one line of the series of lines of energy-activated adhesive aligns with the placement of the backstitches of yam.

54. The method of tufting a primary carpet backing of any preceding claim 41- 53, wherein the backstitch of the tufted yarn overlays the printed energy-activated adhesive on the primary carpet backing.

55. The method of tufting a primary carpet backing of claim 54, wherein an energy-activated formulation is applied over a backstitch of the tufted primary carpet backing.

56. The method of tufting a primary carpet backing of any preceding claim 49-55, wherein the tufted primary carpet backing is exposed to a second source of energy after being exposed to the source of energy, wherein the second source of energy is selected from the group consisting of a source of radiation, a source of heat, or a combination thereof.

57. The method of tufting a primary carpet backing of any preceding claim 41-56, wherein the energy-activated formulation comprises an energy absorbent compound.

58. A soft surface article made from the method of tufting a primary carpet backing of any preceding claim 41-57, wherein the soft surface article is selected from a group consisting of a carpet, a carpet tile, or a rug.

59. A method of tufting a primary carpet backing, consisting of: providing a primary carpet backing; providing a yarn; applying an amount or a dollop of energy-activated formulation to a segment of the yarn while it is being tufted; and tufting the yam through the primary carpet backing; wherein the dollop of energy -activated formulation is laid between subsequent tufts on a backstitch as the primary carpet backing is advanced in a tufting machine.

60. The method of tufting a primary carpet backing of claim 59, wherein the dollop of energy-activated formulation is sandwiched between the yarn and the primary carpet backing on the back side of the primary carpet backing.

61. The method of tufting a primary carpet backing of any preceding claim 59-60, wherein the energy-activated formulation is selected from a group consisting of a radiation-activated formulation, a heat-activated formulation, or a combination thereof.

62. The method of tufting a primary carpet backing of any preceding claim 59-61, wherein the energy-activated formulation becomes molten or pre-gels when exposed to a source of energy.

63. The method of tufting a primary carpet backing of any preceding claim 59-62, wherein the energy-activated formulation becomes flowable when exposed to a source of energy.

64. The method of tufting a primary carpet backing of any preceding claim 59-63, wherein the energy-activated formulation anchors a plurality of filaments from the yam to the primary backing when exposed to a source of energy.

65. The method of tufting a primary carpet backing of any preceding claim 59-64, wherein the source of energy is selected from the group consisting of a source of radiation, a source of heat, or a combination thereof.

66. The method of tufting a primary carpet backing of claim 65, wherein the source of radiation is selected from the group consisting of ultraviolet radiation, infrared radiation, electron beam radiation, visible light, microwave radiation, laser radiation, maser radiation, a guided energy beam, or combinations thereof.

67. The method of tufting a primary carpet backing of any preceding claim 59- 66, wherein the dollop of energy-activated formulation comprises an energy absorbent compound.

68. The method of tufting a primary carpet backing of any preceding claim 59- 67 further comprising exposing the tufted primary carpet backing to a source of energy after tufting the yarn through the primary backing, wherein the source of energy is selected from the group consisting of a source of radiation, a source of heat, or a combination thereof.

69. The method of tufting a primary carpet backing of claim 68, wherein the tufted primary carpet backing is exposed to a second source of energy, wherein the second source of energy is selected from the group consisting of a source of radiation, a source of heat, or a combination thereof.

70. A soft surface article made from the method of tufting a primary carpet backing of any preceding claim 59-69, wherein the soft surface article is selected from a group consisting of a carpet, a carpet tile, or a rug.

71. A soft surface article, wherein said soft surface article is a carpet, a carpet tile or a rug, wherein said soft surface article comprises: a main surface formed by piles of yam; a primary carpet backing, wherein said primary backing is provided with said piles, wherein the side of said primary carpet backing opposite said main surface comprises backstitches of said yam; a spatially distributed adhesive applied to said primary carpet backing at said side thereof opposite said main surface, wherein said spatially distributed adhesive is at least applied over a plurality of said backstitches.

72. The soft surface article of claim 71, wherein said adhesive is an energy- activated or energy-cured adhesive.

73. The soft surface article of claim 71, wherein said adhesive is a multi-part adhesive, such as a two-component adhesive.

74. The soft surface article of claim 73, wherein a first component of said adhesive is comprised in said yarn and / or in said primary backing.

75. The soft surface article of claim 74, wherein only one of the first or second component is spatially distributed.

76. The soft surface article of any of claims 71-75, wherein said adhesive is spatially distributed in a uniform manner.

77. The soft surface article of any of claims 71-76, wherein said adhesive is spatially distributed in a repeating pattern.

78. The soft surface article of any of claims 71-77, wherein said adhesive is spatially distributed in dot wise and / or line wise manner.

79. The soft surface article of any of claims 71-78, wherein said backstitches extend in a first direction along said side opposite said main surface, and wherein said adhesive is spatially distributed in line wise manner, with the lines formed by said adhesive extending at least in a second direction transversal to said first direction.

80. The soft surface article of any of claim 71-79, wherein the spatially distributed adhesive comprises an energy-absorbent compound.

81. The soft surface article of any of claims 71-80, wherein said primary backing comprises a woven or non-woven textile.

82. The soft surface article of any of claims 71-81, wherein said soft surface article further comprise a pad adhered to said side of the primary backing beingopposite said main surface, wherein said pad forms the bottom surface of said soft surface article.

83. The soft surface article of claim 82, wherein said pad is adhered by means of said spatially distributed adhesive.

84. The section of primary carpet backing of any preceding claim 1-40, or the method of tufting a primary carpet backing of any preceding claim 41-69, or the soft surface article of any preceding claim 70-83, wherein the energy-activated formulation comprises a radiation-activated formulation, a heat-activated formulation, or a combination of a radiation-activated formulation and a heat- activated formulation.

85. The article or method of claim 84, wherein the radiation-activated formulation comprises a resin having a viscosity of between 2,000 mPa»s s and 4,000 mPa»s.

86. The article or method of claim 85, wherein the radiation-activated formulation is cured to have a Shore Hardness of between 45A and 70A and an adhesive with a tensile strength of between 2MPa and 5MPa.

87. The article or method of claim 84, wherein the radiation-activated formulation comprises a resin having a viscosity of between 10 mPa»s and 800 mPa»s.

88. The article or method of claim 87, wherein the radiation-activated formulation is cured to have a Shore Hardness of between 70D and 100D and an adhesive with a tensile strength of between 20 MPa and 70 MPa.

89. The article or method of claim 84, wherein the radiation-activated formulation comprises an acrylic-based adhesive selected from the group consistingof a urethane acrylic adhesive, a polyester acrylic adhesive, an epoxy acrylic based adhesive, and combinations thereof.

90. The article or method of claim 84, wherein the heat-activated formulation comprises one or more acrylate reactive diluents and / or methacrylate reactive diluents and / or (meth)acrylamide reactive diluents.

91. The article or method of claim 90, wherein the diluent has a viscosity of between 160 mPa»s and 40 mPa»s when measured at 25°C.

92. The article or method of any preceding claim 90-91, wherein the one or more acrylate reactive diluents and / or methacrylate reactive diluents and / or (meth)acrylamide reactive diluents have an average molar mass higher than 100 g / mol.

93. The article or method of claim 84, wherein the heat-activated formulation comprises a thermally cured acrylate resin, a thermally cured unsaturated polyester resin, and combinations thereof.

94. The article or method of claim 93, wherein the heat-activated formulation is activated by a thermally initiated radical crosslinking reaction.

95. The article or method of claim 84, wherein the radiation-activated formulation comprises a radical-curable coating composition comprising one or more oligomers selected from the group consisting of urethane (meth) acrylates, (meth)acrylated epoxidized triglycerides and any mixture thereof.

96. The article or method of claim 84, wherein the energy-activated formulation comprises a two-part formulation where the parts will not bond, adhere, or react to each other when they are contacted, but will activate when exposed to heat or radiation.

97. The article or method of any preceding claim 84-96, wherein the radiation- activated formulation further comprises a photo-initiator.

98. The article or method of any preceding claim 84-97, wherein the heat- activated formulation further comprises a thermo-initiator.

99. The article or method of any preceding claim 84-98, wherein the energy- activated formulation comprises an energy absorbing compound.

100. A method of applying an energy-activated formulation to a section of a primary carpet backing comprising: providing a woven or nonwoven primary carpet backing; providing an energy-activated formulation; providing a yam; printing the energy-activated formulation on the primary carpet backing in a tufting machine; wherein: the energy-activated formulation is selected from a group consisting of a radiation-activated formulation, a heat-activated formulation, or a combination thereof; and the energy-activated formulation is printed in a plurality of lines where a row of backstitches of the yarn are configured to be laid during a tufting operation of the primary carpet backing.

101. The method of claim 100, wherein the energy-activated formulation is configured to become molten or pre-gels when exposed to a source of energy.

102. The method of claim 100, wherein the energy-activated formulation is configured to become flowable when exposed to a source of energy.

103. The method of claim 100, wherein the energy-activated formulation is configured to become an adhesive when exposed to a source of energy.

104. The method of 103, wherein the source of energy is selected from the group consisting of a source of radiation, a source of heat, or a combination thereof.

105. The method of claim 104, wherein the section of a primary carpet backing is tufted with the yam after the step of printing the energy-activated formulation on the primary carpet.

106. The method of claim 105, wherein the energy-activated formulation comprises a photo-initiator and an acrylic-based adhesive, wherein the acrylic-based adhesive selected from the group consisting of a urethane acrylic adhesive, a polyester acrylic adhesive, an epoxy acrylic based adhesive, and combinations thereof.

107. The method of claim 105, wherein the energy-activated formulation comprises a thermo-initiator and a diluent selected from the group consisting of an acrylate reactive diluent, a methacrylate reactive diluent, and a (meth)acrylamide reactive diluent.

108. The method of claim 105, wherein the energy-activated formulation comprises a photo-initiator, a thermo-initiator, an acrylic-based adhesive, and an acrylate reactive diluent.

109. The method of claim 105, wherein the heat-activated formulation comprises a thermally cured acrylate resin, a thermally cured unsaturated polyester resin, and combinations thereof.

110. The method of claim 109, wherein the heat-activated formulation is activated by a thermally initiated radical crosslinking reaction.

111. The method of claim 105, wherein the radiation-activated formulation comprises a radical-curable coating composition comprising one or more oligomersselected from the group consisting of urethane (meth) acrylates, (meth)acrylated epoxidized triglycerides and any mixture thereof.

112. The method of claim 100, wherein the energy-activated formulation comprises a two-part formulation where the parts will not bond, adhere, or react to each other when they are contacted, but will activate when exposed to heat or radiation.

113. A method of tufting a primary carpet backing, comprising: providing a primary carpet backing comprising a front side and a back side; providing a yarn; providing a tufting machine; applying an amount of a dollop of energy-activated formulation to a segment of the yam while it is being tufted in the tufting machine; and tufting the yarn through the primary carpet backing; wherein the dollop of energy-activated formulation is configured to be laid between subsequent tufts on a backstitch portion of the yarn as the primary carpet backing is advanced in the tufting machine.

114. The method of tufting a primary carpet backing of claim 113, wherein the dollop of energy-activated formulation is sandwiched between the backstitch portion of the yarn and the back side of the primary carpet backing.

115. The method of tufting a primary carpet backing of claim 114, wherein the energy-activated formulation is selected from a group consisting of a radiation- activated formulation, a heat-activated formulation, or a combination thereof.

116. The method of tufting a primary carpet backing of claim 115, wherein the energy-activated formulation is configured to become molten or a gel when exposed to a source of energy.

117. The method of tufting a primary carpet backing of claim 116, wherein the energy-activated formulation is configured to become flowable when exposed to a source of energy.

118. The method of tufting a primary carpet backing of claim 117, wherein the energy-activated formulation is configured to become an adhesive when exposed to a source of energy.

119. The method of tufting a primary carpet backing of claim 118, further comprising exposing the primary carpet backing to a source of energy, wherein the source of energy is selected from the group consisting of a source of radiation, a source of heat, or a combination thereof.

120. A soft surface article, wherein the soft surface article is a carpet, a carpet tile or a rug, comprising: a main surface defined by a pile of yam; a primary carpet backing, wherein a first side of the primary backing is provided with the pile of yam, and wherein a second side of the primary carpet backing is opposite the first side and comprises backstitches of the yarn; a spatially distributed adhesive applied to the primary carpet backing at the second side, wherein the spatially distributed adhesive is at least applied between each backstitch of a plurality of backstitches and the second side of the primary carpet backing.

121. The soft surface article of claim 120, wherein the adhesive is an energy- activated or energy-cured adhesive.

122. The soft surface article of claim 121, wherein the adhesive is a multi-part adhesive, such as a two-component adhesive.

123. The soft surface article of claim 122, wherein a first component of the adhesive is comprised in the yam or in the primary backing.

124. The soft surface article of claim 123, wherein only one of the first or second component is spatially distributed.

125. The soft surface article of claim 124, wherein the adhesive is spatially distributed in a uniform manner.

126. The soft surface article of claim 125, wherein the adhesive is spatially distributed in a repeating pattern.

127. A method of anchoring a yarn to a primary backing, comprising: providing the primary backing; providing the yam; distributing an energy-activated formulation onto a first face the primary carpet backing; tufting the yarn into the primary backing, wherein a plurality of pile loops are formed on a second face of the primary backing, and a plurality of backstitches are formed on the first face of the primary backing; and focusing a guided energy beam towards at least one backstitch of the plurality of backstitches to activate the energy-activated formulation.

128. The method of claim 127, wherein the energy-activated formulation is configured to become an adhesive when exposed to the guided energy beam.

129. The method of 128, wherein a source of the guided energy beam is selected from the group consisting of a laser, and a maser.

130. The method of claim 129, wherein the step of distributing the energy- activated formulation onto a first face the primary carpet backing comprises printingthe energy-activated formulation in a series of lines onto the first face of the primary backing.

131. The method of claim 130, wherein at least one line of the series of lines of energy-activated adhesive printed on the first face of the primary backing aligns with the placement of at least one backstitche of yarn on the first face of the primary backing.

132. The method of claim 129, wherein the step of distributing the energy- activated formulation onto a first face the primary carpet backing comprises applying the energy-activated formulation evenly on the first face of the primary backing.

133. The method of claim 132, wherein the yam comprises an energy-absorbent compound.

134. The method of claim 133, comprising reclaiming an un-activated portion of the energy-activated formulation after the step of focusing a guided energy beam towards at least one backstitch of the plurality of backstitches.

135. A method of tufting a primary carpet backing, comprising: providing a primary carpet backing comprising a front side and a back side; providing a yarn; providing a tufting machine; painting an amount of a dab of energy-activated formulation onto a segment of the yarn while it is being tufted in the tufting machine; tufting the yarn through the primary carpet backing; wherein the amount or the dab of energy-activated formulation is configured to be laid between subsequent tufts on a backstitch portion of the yarn as the primary carpet backing is advanced in the tufting machine; and activating the amount or the dab of energy-activated formulation by applying energy from a guided energy beam.

136. The method of tufting a primary carpet backing of claim 135, wherein the dollop of energy-activated formulation is sandwiched between the backstitch portion of the yam and the back side of the primary carpet backing.

137. The method of tufting a primary carpet backing of claim 136, wherein the energy-activated formulation is configured to become molten or a gel when activated.

138. The method of tufting a primary carpet backing of claim 137, wherein the energy-activated formulation is configured to become flowable when activated.

139. The method of tufting a primary carpet backing of claim 138, wherein the energy-activated formulation is configured to become an adhesive when activated.

140. A soft surface article, wherein the soft surface article is a carpet, a carpet tile or a mg, comprising: a main surface defined by a pile of yam; a primary carpet backing, wherein a first side of the primary backing is provided with the pile of yarn, and wherein a second side of the primary carpet backing is opposite the first side and comprises backstitches of the yarn; a spatially distributed adhesive applied to the primary carpet backing at the second side, wherein the spatially distributed adhesive is at least applied between each backstitch of a plurality of backstitches and the second side of the primary carpet backing.

141. The soft surface article of claim 140, wherein the adhesive is an energy- activated or energy-cured adhesive.

142. The soft surface article of claim 141, wherein the adhesive is a multicomponent adhesive, such as a two-component adhesive.

143. The soft surface article of claim 142, wherein a first component of the adhesive is comprised in the yam or in the primary backing.

144. The soft surface article of claim 143, wherein only one of the first or second component is spatially distributed.

145. The soft surface article of claim 144, wherein the adhesive is spatially distributed in a uniform manner.

146. The soft surface article of claim 145, wherein the adhesive is spatially distributed in a repeating pattern.147.- A method of tufting a primary carpet backing, consisting of: providing a primary carpet backing; and tufting the primary carpet backing with a yam; wherein the primary carpet backing comprises an energy-activated formulated applied thereupon.148.- The method of claim 147, wherein said energy-activated formulation is applied essentially uniformly over a surface of said primary carpet backing.149.- The method of claim 148, wherein said method further comprises topically activating said energy-activated formulation to secure at least one yarn to said primary carpet backing.150.- The method of claim 147, wherein said energy-activated formulation is applied in a spatially distributed manner.151.- The method of claim 150, wherein said method further comprises activating said energy-activated formulation to secure at least one yarn to said primary carpet backing.152.- The method of any of the preceding claims 147 to 151, wherein said energy- activated formulation is printed, roller, spray or curtain coated on said primary backing.

153. The method of any of the preceding claims 147 to 152, wherein the energy- activated formulation is applied on the primary carpet backing before it is loaded into a tufting machine.

154. The method of any of the preceding claims 147 to 152, wherein the energy- activated formulation is applied on the primary carpet backing in a tufting machine.

155. The method of any of the preceding claims 147-154, wherein the energy- activated formulation is selected from a group consisting of a radiation-activated formulation, a heat-activated formulation, or a combination thereof.

156. The method of any of the preceding claims 147 to 155, wherein the energy- activated formulation becomes molten or pre-gels when exposed to a source of energy.157.- The method of any preceding claim 147-156, wherein the energy-activated formulation becomes flowable when exposed to a source of energy.

158. The method of any preceding claim 147-157, wherein the energy-activated formulation becomes an adhesive when exposed to a source of energy.

159. The method of any preceding claim 147-158, wherein the energy-activated formulation is exposed to a source of energy after tufting the primary carpet backing with the yarn.

160. The method of any preceding claim 156 to 159, wherein the source of energy is selected from the group consisting of a source of radiation, a source of heat, or a combination thereof.

161. The method of claim 160, wherein the source of radiation is selected from the group consisting of ultraviolet radiation, infrared radiation, electron beam radiation, visible light, microwave radiation, laser radiation, maser radiation, a guided energy beam, or combinations thereof.

162. The method of any preceding claim 147-161, wherein the energy-activated formulation is a printed energy-activated adhesive printed along a series of lines across the width of the primary carpet backing.

163. The method of claim 162, wherein at least one line of the series of lines across the width of the primary carpet backing is discontiguous along the length of the primary carpet backing.

164. The method of any preceding claim 162-163, wherein at least one line of the series of lines of energy -activated adhesive aligns with the placement of at least one backstitche of yarn.

165. The method of any preceding claim 147-164, wherein the backstitch of the tufted yarn overlays the energy-activated formulation on the primary carpet backing.

166. The method of claim 165, wherein the energy-activated formulation is applied over a backstitch of the tufted primary carpet backing.

167. The method of any preceding claim 159-165, wherein a portion of the energy-activated formulation is unreacted after at least a portion of the primary carpet backing is exposed to the source of energy.

168. The method of claim 167, wherein the unreacted energy-activated formulation is recovered from the primary carpet backing.169.- A soft surface article made from the method of tufting a primary carpet backing of any preceding claim 147-168, wherein the soft surface article is selected from a group consisting of a carpet, a carpet tile, or a rug.