Composite material and carpet composition comprising the same

Abstract

A composite material comprising four layers, two of which are polymeric films and two of which are nonwoven materials, suitable for use as a primary backing material and / or a secondary backing material in the manufacture of a textile carpet composition is disclosed. A method for manufacturing the disclosed composite material is also disclosed.

Description

[0001] Cross Reference to Related Applications

[0002] This application claims the benefit of U.S. Provisional Application No. 63 / 044,467, filed June 26, 2020, which is incorporated by reference herein in its entirety. TECHNICAL FIELD

[0003] The present invention relates to the field of textile carpet compositions, and more particularly, to a composite material suitable for use as a backing component, such as a primary backing component in the manufacture thereof. BACKGROUND

[0004] Traditional carpets are typically woven through a tufting process in which yarns are tufted through a primary backing material. Primary backings commonly used in the carpet industry are typically made of a woven material. However, the manufacture of such woven backings is expensive as it requires expensive equipment and skilled labor trained to weave the backing. Further, to weave the woven material in the weaving process, it is necessary to use warp yarns that are manufactured in a separate manufacturing process using different equipment. While in some cases, the warp yarns can be manufactured from creels located behind the weaving equipment, their production still requires a separate manufacturing step, which makes the entire weaving process complex and inefficient. In some cases, a combination of woven and nonwoven materials can be used to form needle punch backings and nonwoven backings. However, such processes are also expensive as they first require forming the woven material on looms of 12 feet or more at a slow output speed because the weft insertion speed of wide-width weaving is less than 2,500 meters / minute, and then attaching the nonwoven or bonded fibers to the formed woven material in a second processing step. The use of nonwoven materials alone as a backing is not common in the carpet industry as it is well known that nonwoven materials are difficult to repair if an error occurs in the tufting process.

[0005] Accordingly, there remains a need for materials, such as composites, that can be easily and inexpensively manufactured for use as backing materials, such as primary backings in tufted carpets. Further, there remains a need for methods of manufacturing carpets containing such composites. SUMMARY

[0006] The present invention relates generally to a composite material suitable for use as a backing material in the manufacture of textile carpet compositions. Accordingly, in a first aspect, a composite material is disclosed and described herein. The composite material is suitable for use as a primary backing and / or a secondary backing in a carpet composition. For example, the disclosed composite material is suitable for use as a primary backing. In another example, the disclosed composite material is suitable for use as a secondary backing.

[0007] The disclosed composite comprises at least four layers, specifically as follows: a first layer is a continuous or discontinuous first polymeric film having a front side and a back side, wherein the first polymeric film comprises a first polymeric blend comprising a first polymer and a second polymer, wherein the first polymer is immiscible with the second polymer. A second layer is a first nonwoven having a front side and a back side, wherein the front side of the first nonwoven contacts the back side of the first polymeric film. A third layer is a continuous or discontinuous second polymeric film having a front side and a back side, wherein the second polymeric film comprises a second polymeric blend comprising a third polymer and a fourth polymer, wherein the third polymer is immiscible with the fourth polymer, wherein the front side of the second polymeric film contacts the back side of the first nonwoven. A fourth layer is a second nonwoven having a front side and a back side, wherein the front side of the second nonwoven contacts the back side of the second polymeric film. Thus, the composite comprises at least four layers.

[0008] Also disclosed herein is a composite comprising at least four layers, specifically as follows: a first layer is a continuous or discontinuous first polymeric film having a front side and a back side, wherein the first polymeric film comprises a first polymeric blend comprising a first polymer and a second polymer, wherein the first polymer is immiscible with the second polymer. A second layer is a first nonwoven having a front side and a back side. A third layer is a continuous or discontinuous second polymeric film having a front side and a back side, wherein the second polymeric film comprises a second polymeric blend comprising a third polymer and a fourth polymer, wherein the third polymer is immiscible with the fourth polymer. A fourth layer is a second nonwoven having a front side and a back side. The at least four layers can be arranged in any order.

[0009] Also disclosed herein is a composite comprising: a first layer that is a continuous or discontinuous first polymeric film having a front side and a back side, wherein the first polymeric film comprises a first polymeric blend comprising a first polymer and a second polymer, wherein the first polymer is immiscible with the second polymer. A second layer is a first nonwoven having a front side and a back side. A third layer is a continuous or discontinuous second polymeric film having a front side and a back side, wherein the second polymeric film comprises a second polymeric blend comprising a third polymer and a fourth polymer, wherein the third polymer is immiscible with the fourth polymer. The three layers can be arranged in any order.

[0010] Also disclosed is a greige cloth comprising: a) a primary backing material having a front side and a back side. The primary backing material comprises: i) a continuous or discontinuous first polymeric film having a front side and a back side, wherein the first polymeric film comprises a first polymeric blend comprising a first polymer and a second polymer, wherein the first polymer is immiscible with the second polymer; and ii) a continuous or discontinuous second polymeric film having a front side and a back side, wherein the second polymeric film comprises a second polymeric blend comprising a third polymer and a fourth polymer, wherein the third polymer is immiscible with the fourth polymer, wherein the front side of the second polymeric film contacts the back side of the first polymeric film; wherein the first polymeric film is an extruded film and the second polymeric film is an extruded film, wherein the first polymeric film and the second polymeric film are extruded in directions that are transverse to each other. The greige cloth further comprises: b) a plurality of fibers attached to the primary backing material, at least a portion of the plurality of fibers extending from the front side of the primary backing material to form a pile side.

[0011] In another aspect, a method for manufacturing the composite materials described herein is provided.

[0012] In another aspect, a textile carpet composition comprising the composite materials described herein is disclosed.

[0013] In another aspect, a greige cloth comprising the composite materials described herein is disclosed.

[0014] In still another aspect, a method of manufacturing the disclosed carpet composition is provided.

[0015] Additional aspects of the application will be set forth in part in the description which follows, and in part will be apparent from the description, or can be learned by practice of the application. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the application as disclosed. BRIEF DESCRIPTION OF DRAWINGS

[0016] Figure 1A and 1B A yarn is shown tufted with the non-limiting composite material disclosed herein. Figure 1A A front side of the composite material is shown with tufted yarns. Figure 1B A back side of the composite material is shown with tufted yarns.

[0017] Figure 2A and 2B A yarn is shown tufted with the non-limiting composite material disclosed herein. Figure 2A A front side of the composite material is shown with tufted yarns. Figure 2B A back side of the composite material is shown with tufted yarns.

[0018] Figure 3 Non-limiting examples of carpet compositions disclosed herein are shown. DETAILED DESCRIPTION

[0019] The present application can be more easily understood and further advantages and benefits can be obtained, by reference to the following detailed description, examples, drawings and claims, as well as the description before and after. However, before the compositions, articles, devices, systems and / or methods of the present application are disclosed and described, it is to be understood that the application is not limited to the specific compositions, articles, devices, systems and / or methods disclosed unless otherwise specified, as such can, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting.

[0020] The following description of the application also is provided for the purposes of enabling those with ordinary skill in the relevant art to make and use the application and is provided with the recognition that variations and modifications of the various aspects of the application described herein can be made once the benefits of the present application have been realized. It should be noted, however, that any anticipated or unanticipated permutations of the application or its likeness are to be considered as being within the scope of the application. It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting.

[0021] The present application encompasses various combinations of the elements of the disclosure, e.g., combinations of elements from dependent claims referring to the same independent claim.

[0022] Furthermore, it should be understood that any method disclosed herein need not necessarily be performed in the order described. Accordingly, unless otherwise specified, it is to be understood that the order of steps can be modified and that the modified order is to be considered an embodiment of the application. Also, it is to be understood that the described steps can be combined and / or divided into additional steps not otherwise described. Thus, the scope of the application should be determined by the appended claims and the legal equivalents thereof, rather than by the description of the aspects.

[0023] All publications mentioned herein are incorporated herein by reference to disclose and describe the methods and / or materials in connection with which the publications are cited.

[0024] It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting. As used in the specification and in the claims, the term "comprising" can include the aspects "consisting of and "consisting essentially of." Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs. In this specification and in the claims that follow, reference will be made to a number of terms, which shall have the definitions set out below.

[0025] As used herein, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to "a polymer" includes aspects having two or more polymers unless the context clearly indicates otherwise.

[0026] Ranges can be expressed herein as from "about" one particular value, and / or to "about" another particular value. When such ranges are expressed, another aspect includes from the one particular value and / or to the other particular value. Similarly, when values are expressed as approximations by use of the antecedent "about," it will be understood that the particular value forms another aspect. It will be further understood that each end point of the ranges is significantly close to the other, and independently of the other end point. It will be also understood that numerous values have been disclosed, and each of those values is disclosed as "about that particular value" in addition to the value itself. For example, if the value "10" is disclosed, then "about 10" is also disclosed. It will be also understood that each unit between two particular units is also disclosed. For example, if 10 and 15 are disclosed, then 11, 12, 13, and 14 are also disclosed.

[0027] As used herein, the term "optional" or "optionally" means that the subsequently described event or circumstance can or can not occur, and that the description includes instances where the event or circumstance occurs and instances where it does not.

[0028] As used herein, "carpet composition" includes carpet floor coverings of various constructions or forms. For example, and without limitation, the term "carpet composition" includes carpet webbing, carpet tiles, broadloom carpet, area rug, and artificial turf. In this regard, "broadloom carpet" refers to a broadloom textile floor product manufactured in roll form.

[0029] The definition of carpet composition herein excludes products known to one of ordinary skill in the art as "resilient flooring." By way of example, products falling into the category of resilient flooring include, but are not limited to, linoleum, vinyl tile, cork tile, rubber tile, and floor mat.

[0030] As used herein, the term "by weight," when used in connection with a component, is based on the total weight of the formulation or composition including the component, unless specifically stated to the contrary. For example, if a particular element or component in a composition or article is said to be present by weight in an amount of 8%, it is understood that the percentage is a percentage relative to 100% total composition.

[0031] Unless specifically stated to the contrary, a weight percent, or wt.%, or %wt. of a component, is based on the total weight of the formulation or composition including the component.

[0032] Whereas the weight parts of a particular element or component in a composition or article are referred to in the specification and concluding claims, this indicates the weight relationship between the element or component and any other elements or components in the composition or article for which a weight part is expressed. Thus, in a composition or selected portion of a composition containing 2 parts by weight of X component and 5 parts by weight of Y component, X and Y are present at a weight ratio of 2:5 and are present in that ratio regardless of whether any other components are contained in the composition.

[0033] In some cases, the weight parts of a component are based on the weight of the composition "on a dry basis," and thus, it refers to "dry parts," which indicates the weight parts of the composition without water or any other liquid or fluid.

[0034] In other cases, the weight parts of a component are based on the weight of the composition "on a wet basis," and thus, it refers to "wet parts," which indicates the weight parts of the composition in the presence of water or any other liquid or fluid.

[0035] As used herein, the term "fiber" includes fibers of indefinite or very long length (i.e., filaments) and fibers of short length.

[0036] As used herein, the term "yarn" refers to a continuous strand or bundle of fibers.

[0037] While aspects of the present application can be described and claimed in particular combinations, it is understood that these combinations are not exclusive and that various aspects of the present application can be described and claimed in different combinations. It is therefore not intended to use the phrase "at least one of A and B" to mean that "A or B, but not both." Rather, the phrase "at least one of A and B" should be taken to mean "A or B or both," unless otherwise stated. Similarly, the phrase "at least one of A, B, and C" should be taken to mean "A or B or C or any combination thereof," unless otherwise stated. The phrase "one or more of A, B, and C" should be taken to mean "at least one of A, at least one of B, and at least one of C," unless otherwise stated. While aspects of the present application can be described and claimed in particular combinations, it is understood that these combinations are not exclusive and that various aspects of the present application can be described and claimed in different combinations. It is therefore not intended to use the phrase "at least one of A and B" to mean that "A or B, but not both." Rather, the phrase "at least one of A and B" should be taken to mean "A or B or both," unless otherwise stated. Similarly, the phrase "at least one of A, B, and C" should be taken to mean "A or B or C or any combination thereof," unless otherwise stated. The phrase "one or more of A, B, and C" should be taken to mean "at least one of A, at least one of B, and at least one of C," unless otherwise stated.

[0038] A. Composite suitable for primary and / or secondary backing

[0039] As noted above, the present application is directed, in part, to a composite. The composite is suitable and can be used as a primary backing component in the manufacture of carpet compositions. As disclosed herein, the present application is also directed, in part, to the use of the composite as a primary backing component in the manufacture of carpet compositions. The disclosed composite is also suitable for use as a secondary backing component in carpet compositions.

[0040] Disclosed herein is a composite comprising: (a) a continuous or discontinuous first polymeric film having a front side and a back side, wherein the first polymeric film comprises a first polymeric blend comprising a first polymer and a second polymer, wherein the first polymer is immiscible with the second polymer; (b) a first nonwoven having a front side and a back side, wherein the front side of the first nonwoven contacts the back side of the first polymeric film; (c) a continuous or discontinuous second polymeric film having a front side and a back side, wherein the second polymeric film comprises a second polymeric blend comprising a third polymer and a fourth polymer, wherein the third polymer is immiscible with the fourth polymer, wherein the front side of the second polymeric film contacts the back side of the first nonwoven; and (d) a second nonwoven having a front side and a back side, wherein the front side of the second nonwoven contacts the back side of the second polymeric film. Thus, the composite comprises at least four layers.

[0041] In one aspect, the composite consists of: (a) a continuous or discontinuous first polymeric film having a front side and a back side, wherein the first polymeric film comprises a first polymeric blend comprising a first polymer and a second polymer, wherein the first polymer is immiscible with the second polymer; (b) a first nonwoven having a front side and a back side, wherein the front side of the first nonwoven contacts the back side of the first polymeric film; (c) a continuous or discontinuous second polymeric film having a front side and a back side, wherein the second polymeric film comprises a second polymeric blend comprising a third polymer and a fourth polymer, wherein the third polymer is immiscible with the fourth polymer, wherein the front side of the second polymeric film contacts the back side of the first nonwoven; and (d) a second nonwoven having a front side and a back side, wherein the front side of the second nonwoven contacts the back side of the second polymeric film.

[0042] Disclosed herein is a composite comprising: a) a continuous or discontinuous first polymeric film having a front side and a back side, wherein the first polymeric film comprises a first polymeric blend comprising a first polymer and a second polymer, wherein the first polymer is immiscible with the second polymer; b) a first nonwoven having a front side and a back side; c) a continuous or discontinuous second polymeric film having a front side and a back side, wherein the second polymeric film comprises a second polymeric blend comprising a third polymer and a fourth polymer, wherein the third polymer is immiscible with the fourth polymer; and d) a second nonwoven having a front side and a back side. For example, the composite of this aspect can consist of: a) a continuous or discontinuous first polymeric film having a front side and a back side, wherein the first polymeric film comprises a first polymeric blend comprising a first polymer and a second polymer, wherein the first polymer is immiscible with the second polymer; b) a first nonwoven having a front side and a back side; c) a continuous or discontinuous second polymeric film having a front side and a back side, wherein the second polymeric film comprises a second polymeric blend comprising a third polymer and a fourth polymer, wherein the third polymer is immiscible with the fourth polymer; and d) a second nonwoven having a front side and a back side. The layers in the composite can be arranged in any order. In one aspect, the front side of the second polymeric film contacts the back side of the first polymeric film. In another aspect, the front side of the first polymeric film contacts the back side of the first nonwoven. In yet another aspect, the front side of the second nonwoven contacts the back side of the first polymeric film. In yet another aspect, the front side of the first nonwoven contacts the back side of the second nonwoven. In yet another aspect, the front side of the first nonwoven contacts the back side of the second polymeric film. In yet another aspect, the front side of the second nonwoven contacts the back side of the first nonwoven. In yet another aspect, the front side of the first nonwoven contacts the back side of the first polymeric film. In yet another aspect, the front side of the second nonwoven contacts the back side of the first nonwoven. In yet another aspect, the front side of the second polymeric film contacts the back side of the second nonwoven. In yet another aspect, the front side of the first polymeric film contacts the back side of the first nonwoven. In yet another aspect, the front side of the second nonwoven contacts the back side of the first polymeric film. In yet another aspect, the front side of the second polymeric film contacts the back side of the second nonwoven.

[0043] Also disclosed herein is a composite material comprising: a) a continuous or discontinuous first polymeric film having a front side and a back side, wherein the first polymeric film comprises a first polymeric blend comprising a first polymer and a second polymer, wherein the first polymer is immiscible with the second polymer; b) a first nonwoven having a front side and a back side; and c) a continuous or discontinuous second polymeric film having a front side and a back side, wherein the second polymeric film comprises a second polymeric blend comprising a third polymer and a fourth polymer, wherein the third polymer is immiscible with the fourth polymer. For example, the composite material can consist of: a) a continuous or discontinuous first polymeric film having a front side and a back side, wherein the first polymeric film comprises a first polymeric blend comprising a first polymer and a second polymer, wherein the first polymer is immiscible with the second polymer; b) a first nonwoven having a front side and a back side; and c) a continuous or discontinuous second polymeric film having a front side and a back side, wherein the second polymeric film comprises a second polymeric blend comprising a third polymer and a fourth polymer, wherein the third polymer is immiscible with the fourth polymer. The layers in the composite material can be arranged in any order. In one aspect, the front side of the second polymeric film contacts the back side of the first polymeric film. In another aspect, the front side of the first polymeric film contacts the back side of the first nonwoven. In yet another aspect, the front side of the first nonwoven contacts the back side of the second polymeric film. In yet another aspect, the front side of the first nonwoven contacts the back side of the first polymeric film. In yet another aspect, the front side of the second polymeric film contacts the back side of the first nonwoven.

[0044] In one aspect, the composite material can have a front side and a back side, wherein the front side of the composite material is the front side of the first polymeric film, and wherein the back side of the composite material is the back side of the second nonwoven.

[0045] In one aspect, the composite material is a laminated composite material.

[0046] The continuous or discontinuous first polymeric film comprises a polymer (e.g., the first polymer) that is immiscible with another polymer (e.g., the second polymer), which means that there is phase separation between the polymers in the first polymeric film. Similarly, the continuous or discontinuous second polymeric film comprises a polymer (e.g., the third polymer) that is immiscible with another polymer (e.g., the fourth polymer), which means that there is phase separation between the polymers in the second polymeric film.

[0047] A continuous first or second polymer film is a regular polymer film in the sense that it has not been intentionally physically altered, such as by delamination or holes. A non-continuous first or second polymer film is a polymer film that has been physically altered, such as by containing delaminations or holes. For example, a non-continuous first or second polymer film can be prepared by treating a continuous polymer film with a high pressure water jet to form delaminations in the continuous film. A non-continuous first or second polymer film can be a fibrous film.

[0048] In one aspect, the composite material comprises a continuous first polymer film. In another aspect, the composite material comprises a continuous second polymer film. In yet another aspect, the composite material comprises a continuous first polymer film and a continuous second polymer film. In yet another aspect, the composite material comprises a non-continuous first polymer film. In yet another aspect, the composite material comprises a non-continuous second polymer film. In yet another aspect, the composite material comprises a non-continuous first polymer film and a non-continuous second polymer film. In yet another aspect, the composite material comprises a non-continuous first polymer film and a continuous second film. In yet another aspect, the composite material comprises a continuous first polymer film and a non-continuous second polymer film.

[0049] In one aspect, the continuous or non-continuous first polymer film is an extruded film. In one aspect, the continuous or non-continuous second polymer film is an extruded film. In one aspect, the continuous or non-continuous first polymer film is an extruded film and the continuous or non-continuous second polymer film is an extruded film.

[0050] In one aspect, the continuous or non-continuous first polymer film is an extruded film and the continuous or non-continuous second polymer film is an extruded film, wherein the continuous or non-continuous first polymer film and the continuous or non-continuous second polymer film are extruded in the same direction. For example, the continuous or non-continuous first polymer film and the continuous or non-continuous second polymer film can both be extruded in the machine direction.

[0051] In one aspect, the continuous or non-continuous first polymer film is an extruded film and the continuous or non-continuous second polymer film is an extruded film, wherein the continuous or non-continuous first polymer film and the continuous or non-continuous second polymer film are extruded in the cross direction. For example, the continuous or non-continuous first polymer film can be extruded in the machine direction and the continuous or non-continuous second polymer film can be extruded in the cross direction.

[0052] In one aspect, the continuous or non-continuous first polymer film is a stretched film and the continuous or non-continuous second polymer film is a stretched film, wherein the continuous or non-continuous first polymer film and the continuous or non-continuous second polymer film are stretched in the same direction. For example, the continuous or non-continuous first polymer film and the continuous or non-continuous second polymer film can both be stretched in the machine direction.

[0053] In an aspect, the first continuous or non-continuous polymer film is a stretched film and the second continuous or non-continuous polymer film is a stretched film, wherein the first continuous or non-continuous polymer film and the second continuous or non-continuous polymer film are stretched in a cross direction. For example, the first continuous or non-continuous polymer film can be stretched in a machine direction and the second continuous or non-continuous polymer film can be stretched in a cross direction.

[0054] For example, the first continuous or non-continuous polymer film and / or the second continuous or non-continuous polymer film can be stretched 2X to 10X, or 3X to 7X, or 4X to 6X, if not stretched, the defined length.

[0055] In an aspect, the first polymer blend and the second polymer blend are substantially the same. In such an aspect, the first polymer in the first polymer blend is substantially the same as the third polymer in the second polymer blend and the second polymer in the first polymer blend is substantially the same as the fourth polymer in the second polymer blend, and the ratio of the first polymer to the second polymer in the first polymer blend is substantially the same as the ratio of the third polymer to the fourth polymer in the second polymer blend.

[0056] In an aspect, the first polymer blend and the second polymer blend are distinguishable from one another. The first polymer blend and the second polymer blend can be distinguishable by the polymers that make up the first polymer blend and the second polymer blend, or by the ratio of the polymers used to make the first polymer blend and the second polymer blend.

[0057] In one aspect, the first polymer blend comprises about 1 wt% to about 99 wt% of the first polymer and about 99 wt% to about 1 wt% of the second polymer. For example, the first polymer blend can comprise about 5 wt% to about 99 wt% of the first polymer and about 95 wt% to about 1 wt% of the second polymer. In another example, the first polymer blend can comprise about 10 wt% to about 99 wt% of the first polymer and about 90 wt% to about 1 wt% of the second polymer. In yet another example, the first polymer blend can comprise about 20 wt% to about 99 wt% of the first polymer and about 80 wt% to about 1 wt% of the second polymer. In yet another example, the first polymer blend can comprise about 30 wt% to about 99 wt% of the first polymer and about 70 wt% to about 1 wt% of the second polymer. In yet another example, the first polymer blend can comprise about 40 wt% to about 99 wt% of the first polymer and about 60 wt% to about 1 wt% of the second polymer. In yet another example, the first polymer blend can comprise about 50 wt% to about 99 wt% of the first polymer and about 50 wt% to about 1 wt% of the second polymer. In yet another example, the first polymer blend can comprise about 60 wt% to about 99 wt% of the first polymer and about 40 wt% to about 1 wt% of the second polymer. In yet another example, the first polymer blend can comprise about 70 wt% to about 99 wt% of the first polymer and about 30 wt% to about 1 wt% of the second polymer. In yet another example, the first polymer blend can comprise about 80 wt% to about 99 wt% of the first polymer and about 20 wt% to about 1 wt% of the second polymer.

[0058] In another example, the first polymer blend can include from about 1 wt% to about 95 wt% of the first polymer and from about 99 wt% to about 5 wt% of the second polymer. In another example, the first polymer blend can include from about 1 wt% to about 90 wt% of the first polymer and from about 99 wt% to about 10 wt% of the second polymer. In yet another example, the first polymer blend can include from about 1 wt% to about 80 wt% of the first polymer and from about 99 wt% to about 20 wt% of the second polymer. In yet another example, the first polymer blend can include from about 1 wt% to about 70 wt% of the first polymer and from about 99 wt% to about 30 wt% of the second polymer. In yet another example, the first polymer blend can include from about 1 wt% to about 60 wt% of the first polymer and from about 99 wt% to about 40 wt% of the second polymer. In yet another example, the first polymer blend can include from about 1 wt% to about 50 wt% of the first polymer and from about 99 wt% to about 50 wt% of the second polymer. In yet another example, the first polymer blend can include from about 1 wt% to about 40 wt% of the first polymer and from about 99 wt% to about 60 wt% of the second polymer. In yet another example, the first polymer blend can include from about 1 wt% to about 30 wt% of the first polymer and from about 99 wt% to about 70 wt% of the second polymer. In yet another example, the first polymer blend can include from about 1 wt% to about 20 wt% of the first polymer and from about 99 wt% to about 80 wt% of the second polymer. In yet another aspect, the first polymer blend can include from about 5 wt% to about 50 wt% of the first polymer and from about 95 wt% to about 50 wt% of the second polymer. In yet another aspect, the first polymer blend can include from about 20 wt% to about 30 wt% of the first polymer and from about 80 wt% to about 70 wt% of the second polymer.

[0059] In one aspect, the second polymer blend comprises about 1 wt% to about 99 wt% of the third polymer and about 99 wt% to about 1 wt% of the fourth polymer. For example, the second polymer blend can comprise about 5 wt% to about 99 wt% of the third polymer and about 95 wt% to about 1 wt% of the fourth polymer. In another example, the second polymer blend can comprise about 10 wt% to about 99 wt% of the third polymer and about 90 wt% to about 1 wt% of the fourth polymer. In yet another example, the second polymer blend can comprise about 20 wt% to about 99 wt% of the third polymer and about 80 wt% to about 1 wt% of the fourth polymer. In yet another example, the second polymer blend can comprise about 30 wt% to about 99 wt% of the third polymer and about 70 wt% to about 1 wt% of the fourth polymer. In yet another example, the second polymer blend can comprise about 40 wt% to about 99 wt% of the third polymer and about 60 wt% to about 1 wt% of the fourth polymer. In yet another example, the second polymer blend can comprise about 50 wt% to about 99 wt% of the third polymer and about 50 wt% to about 1 wt% of the fourth polymer. In yet another example, the second polymer blend can comprise about 60 wt% to about 99 wt% of the third polymer and about 40 wt% to about 1 wt% of the fourth polymer. In yet another example, the second polymer blend can comprise about 70 wt% to about 99 wt% of the third polymer and about 30 wt% to about 1 wt% of the fourth polymer. In yet another example, the second polymer blend can comprise about 80 wt% to about 99 wt% of the third polymer and about 20 wt% to about 1 wt% of the fourth polymer.

[0060] In another example, the second polymer blend can include about 1 wt% to about 95 wt% of the third polymer and about 99 wt% to about 5 wt% of the fourth polymer. In another example, the second polymer blend can include about 1 wt% to about 90 wt% of the third polymer and about 99 wt% to about 10 wt% of the fourth polymer. In yet another example, the second polymer blend can include about 1 wt% to about 80 wt% of the third polymer and about 99 wt% to about 20 wt% of the fourth polymer. In yet another example, the second polymer blend can include about 1 wt% to about 70 wt% of the third polymer and about 99 wt% to about 30 wt% of the fourth polymer. In yet another example, the second polymer blend can include about 1 wt% to about 60 wt% of the third polymer and about 99 wt% to about 40 wt% of the fourth polymer. In yet another example, the second polymer blend can include about 1 wt% to about 50 wt% of the third polymer and about 99 wt% to about 50 wt% of the fourth polymer. In yet another example, the second polymer blend can include about 1 wt% to about 40 wt% of the third polymer and about 99 wt% to about 60 wt% of the fourth polymer. In yet another example, the second polymer blend can include about 1 wt% to about 30 wt% of the third polymer and about 99 wt% to about 70 wt% of the fourth polymer. In yet another example, the second polymer blend can include about 1 wt% to about 20 wt% of the third polymer and about 99 wt% to about 80 wt% of the fourth polymer. In yet another aspect, the second polymer blend can include about 5 wt% to about 50 wt% of the third polymer and about 95 wt% to about 50 wt% of the fourth polymer. In yet another aspect, the second polymer blend can include about 20 wt% to about 30 wt% of the third polymer and about 80 wt% to about 70 wt% of the fourth polymer.

[0061] In one aspect, the continuous or non-continuous first polymer film can include two or more alternating layers of the first polymer and the second polymer. For example, the continuous or non-continuous first polymer film can include 10 or more alternating layers of the first polymer and the second polymer. In another example, the continuous or non-continuous first polymer film can include 100 or more alternating layers of the first polymer and the second polymer. In yet another example, the continuous or non-continuous first polymer film can include 1,000 or more alternating layers of the first polymer and the second polymer. In yet another example, the continuous or non-continuous first polymer film can include 5,000 or more alternating layers of the first polymer and the second polymer. The alternating layers of the first and second polymers can be accomplished by a doubling method, in which layers of the first polymer and the second polymer are folded multiple times to create multiple alternating layers of the first polymer and the second polymer in the first polymer blend.

[0062] In an aspect, the continuous or non-continuous first polymeric film can include filaments of the first polymer within a continuous phase of the second polymer. For example, the filaments of the first polymer can be randomly oriented within the continuous phase of the second polymer. In another example, the filaments of the first polymer can be aligned within the continuous phase of the second polymer. In another example, the filaments of the first polymer can be substantially uniformly distributed within the continuous phase of the second polymer. In such aspects, an extrusion process operating at a constant polymer output can be used such that a predetermined amount of the first polymer and the second polymer are extruded under constant conditions such that the first polymer can be substantially uniformly distributed within the continuous phase of the second polymer.

[0063] In an aspect, the continuous or non-continuous first polymeric film can include filaments of the second polymer within a continuous phase of the first polymer. For example, the filaments of the second polymer can be randomly oriented within the continuous phase of the first polymer. In another example, the filaments of the second polymer can be aligned within the continuous phase of the first polymer. In another example, the filaments of the second polymer can be substantially uniformly distributed within the continuous phase of the first polymer. In such aspects, an extrusion process operating at a constant polymer output can be used such that a predetermined amount of the first polymer and the second polymer are extruded under constant conditions such that the second polymer can be substantially uniformly distributed within the continuous phase of the first polymer.

[0064] In an aspect, the continuous or non-continuous second polymeric film can include two or more alternating layers of a third polymer and a fourth polymer. For example, the continuous or non-continuous second polymeric film can include 10 or more alternating layers of a third polymer and a fourth polymer. In another example, the continuous or non-continuous second polymeric film can include 100 or more alternating layers of a third polymer and a fourth polymer. In yet another example, the continuous or non-continuous second polymeric film can include 1,000 or more alternating layers of a third polymer and a fourth polymer. In yet another example, the continuous or non-continuous second polymeric film can include 5,000 or more alternating layers of a third polymer and a fourth polymer. The alternating layers of the third and fourth polymers can be accomplished by a doubling method, in which a layer of the third polymer and the fourth polymer is folded multiple times to create multiple alternating layers of the third polymer and the fourth polymer in the third polymer blend.

[0065] In an aspect, the continuous or non-continuous second polymeric film can include filaments of a third polymer within a continuous phase of the fourth polymer. For example, the filaments of the third polymer can be randomly oriented within the continuous phase of the fourth polymer. In another example, the filaments of the third polymer can be aligned within the continuous phase of the fourth polymer. In another example, the filaments of the third polymer can be substantially uniformly distributed within the continuous phase of the fourth polymer. In such an aspect, an extrusion process operating at a constant polymer output can be used such that a pre-set amount of the third polymer and the fourth polymer are extruded under constant conditions such that the third polymer can be substantially uniformly distributed within the continuous phase of the fourth polymer.

[0066] In an aspect, the continuous or non-continuous second polymeric film can include filaments of a fourth polymer within a continuous phase of the third polymer. For example, the filaments of the fourth polymer can be randomly oriented within the continuous phase of the third polymer. In another example, the filaments of the fourth polymer can be aligned within the continuous phase of the third polymer. In another example, the filaments of the fourth polymer can be substantially uniformly distributed within the continuous phase of the third polymer. In such an aspect, an extrusion process operating at a constant polymer output can be used such that a pre-set amount of the third polymer and the fourth polymer are extruded under constant conditions such that the fourth polymer can be substantially uniformly distributed within the continuous phase of the third polymer.

[0067] In an aspect, the continuous or non-continuous first polymeric film can have a thickness of about 25 pm to about 500 pm. For example, the continuous or non-continuous first polymeric film can have a thickness of about 50 pm to about 400 pm. In another example, the continuous or non-continuous first polymeric film can have a thickness of about 100 pm to about 200 pm. In another example, the continuous or non-continuous first polymeric film can have a thickness of about 75 pm to about 300 pm.

[0068] In an aspect, the continuous or non-continuous second polymeric film can have a thickness of about 25 pm to about 500 pm. For example, the continuous or non-continuous second polymeric film can have a thickness of about 50 pm to about 400 pm. In another example, the continuous or non-continuous second polymeric film can have a thickness of about 100 pm to about 200 pm. In another example, the continuous or non-continuous second polymeric film can have a thickness of about 75 pm to about 300 pm.

[0069] In an aspect, the first polymer is a polyester, a polyamide, or a polystyrene, or a combination thereof. For example, the first polymer can be a polyester. In such an example, the polyester can be polyethylene terephthalate. In another example, the first polymer can be a polyamide. In such an example, the polyamide can be selected from the group consisting of polyamide 6, polyamide 11, polyamide 12, copolymers thereof, and blends thereof. In yet another example, the first polymer can be a polystyrene.

[0070] In an aspect, the second polymer can be a polyolefin. In such an aspect, the polyolefin can be selected from the group consisting of polyethylene, polypropylene, polybutylene, copolymers thereof, and blends thereof. For example, the second polymer can be polyethylene. In another example, the second polymer can be polypropylene. In yet another example, the second polymer can be polybutylene.

[0071] In an aspect, the first polymer can be polyethylene terephthalate and the second polymer can be polypropylene. In an aspect, the first polymer can be polystyrene and the second polymer can be polypropylene.

[0072] In an aspect, the third polymer is a polyester, a polyamide, or a polystyrene, or a combination thereof. For example, the third polymer can be a polyester. In such an example, the polyester can be polyethylene terephthalate. In another example, the third polymer can be a polyamide. In such an example, the polyamide can be selected from the group consisting of polyamide 6, polyamide 11, polyamide 12, copolymers thereof, and blends thereof. In yet another example, the third polymer can be a polystyrene.

[0073] In an aspect, the fourth polymer can be a polyolefin. In such an aspect, the polyolefin can be selected from the group consisting of polyethylene, polypropylene, polybutylene, copolymers thereof, and blends thereof. For example, the fourth polymer can be polyethylene. In another example, the fourth polymer can be polypropylene. In yet another example, the fourth polymer can be polybutylene.

[0074] In an aspect, the third polymer can be polyethylene terephthalate and the fourth polymer can be polypropylene. In an aspect, the third polymer can be polystyrene and the fourth polymer can be polypropylene.

[0075] In an aspect, the first nonwoven fabric comprises a spunbond nonwoven material. In another aspect, the first nonwoven fabric comprises a stabilizing fiber. Spunbond nonwoven materials are available from many commercial sources, including 3M, Avgol, and Berry Global. In an aspect, the first nonwoven fabric has a weight of from about 10 gsm to about 40 gsm.

[0076] In one aspect, the second nonwoven fabric comprises a spunbond nonwoven material. In another aspect, the second nonwoven fabric comprises a stabilizing fiber. In one aspect, the second nonwoven fabric has a weight of from about 10 gsm to about 40 gsm.

[0077] B. Carpet Composition

[0078] The present disclosure further provides a carpet composition comprising the composite material disclosed and described above. In some aspects, the carpet composition generally comprises the composite material as a primary backing component. In other aspects, the composite material can be present as a secondary backing component. The carpet composition can be a tufted carpet or a non-tufted carpet, such as a needle punch carpet. To form a tufted carpet, yarns are tufted through a primary backing component such that a longer length of each stitch extends through the surface of the primary backing component. The primary backing component can be any of the composite materials described herein.

[0079] It has been discovered that the carpet compositions described herein can be provided with desirable properties when the carpet composition comprises the composite materials disclosed herein.

[0080] Examples of tufting yarns into the composite materials as disclosed herein are shown in Figures 1A-1B and 2A-2B.

[0081] In one aspect, disclosed herein is a carpet composition comprising a primary backing material, wherein the primary backing material can be a composite material disclosed herein.

[0082] In one aspect, disclosed herein is a carpet composition comprising a secondary backing material, wherein the secondary backing material can be a composite material disclosed herein.

[0083] In one aspect, disclosed herein is a carpet composition comprising a primary backing material and a secondary backing material, wherein the primary backing material can be a composite material disclosed herein and the secondary backing material can be a composite material disclosed herein.

[0084] In one aspect, disclosed herein is a greige good comprising: a) a primary backing material having a face side and a back side, wherein the primary backing material is a composite material disclosed herein; and b) a plurality of fibers attached to the primary backing material, at least a portion of the plurality of fibers extending from the face side of the primary backing material to form a pile face. In one aspect, the greige good further comprises a pre-coat composition applied to the back side of the primary backing material; and a secondary backing material having a face side and a back side, wherein the face side of the secondary backing material is adjacent to the pre-coat composition. For example, the secondary backing material can be a composite material disclosed herein. In another aspect, the secondary backing material is not a composite material disclosed herein. In a further aspect, a polymeric film is applied to the back side of the secondary backing material.

[0085] In one aspect, disclosed herein is a greige cloth comprising: a) a primary backing material having a front side and a back side; and b) a plurality of fibers attached to the primary backing material, at least a portion of the plurality of fibers extending from the front side of the primary backing material to form a pile side; c) a precoat composition applied to the back side of the primary backing material; and d) a secondary backing material having a front side and a back side, wherein the front side of the secondary backing material is adjacent to the precoat composition, and wherein the secondary backing material is a composite material disclosed herein. In one aspect, the primary backing material is not a composite material disclosed herein. In a further aspect, a polymeric film is applied to the back side of the secondary backing material.

[0086] In one aspect, disclosed herein is a greige cloth comprising: a) a primary backing material having a front side and a back side, wherein the primary backing material comprises: i) a continuous or discontinuous first polymeric film having a front side and a back side, wherein the first polymeric film comprises a first polymeric blend comprising a first polymer and a second polymer, wherein the first polymer is immiscible with the second polymer; and ii) a continuous or discontinuous second polymeric film having a front side and a back side, wherein the second polymeric film comprises a second polymeric blend comprising a third polymer and a fourth polymer, wherein the third polymer is immiscible with the fourth polymer, wherein the front side of the second polymeric film contacts the back side of the first polymeric film; wherein the first polymeric film is an extruded film and the second polymeric film is an extruded film; wherein the first polymeric film and the second polymeric film are extruded in a direction transverse to the cross direction, and b) a plurality of fibers attached to the primary backing material, at least a portion of the plurality of fibers extending from the front side of the primary backing material to form a pile side. In one aspect, the greige cloth can further comprise c) a precoat composition applied to the back side of the primary backing material; and d) a secondary backing material having a front side and a back side, wherein the front side of the secondary backing material is adjacent to the precoat composition. In yet another aspect, the greige cloth can further comprise e) a polymeric film applied to the back side of the secondary backing material.

[0087] In certain aspects, when the secondary backing is a composite material disclosed herein, the primary backing material is not a composite primary backing material. In those aspects, the primary backing component comprises a polyolefin, a polyester, a polyamide, or a combination thereof. The primary backing component can be woven and nonwoven. In certain aspects, the primary backing component can comprise a nonwoven fibrous web or a spunbond material. In some aspects, the primary backing component can comprise a combination of woven and nonwoven materials. In some aspects, the primary backing component comprises a polyolefin polymer. In other aspects, the polyolefin polymer comprises polypropylene. In yet other aspects, the primary backing component is a slit film polypropylene sheet, such as slit film polypropylene sheets sold under the trade name Propex or Synthetic Industries owned by Shaw Industries. In yet further aspects, the primary backing component can comprise a polyester. In still further aspects, the primary backing component can comprise a polyamide. In yet further aspects, the primary backing component can comprise a combination of a polyamide and a polyester. In certain aspects, the polyamide is nylon. In some other aspects, the primary backing can comprise a woven polyethylene terephthalate (PET). In yet other aspects, the primary backing can comprise a woven PET having post-consumer and / or post-industrial content.

[0088] In certain aspects, the primary backing component is a spunbond primary backing component. Spunbond backings can be produced by depositing extruded filaments in a uniform random manner onto a collection belt, then bonding the fibers. During web laydown, the fibers are separated by air jets or electrostatic charge. The collection surface is typically porous to prevent air flow from deflecting and carrying the fibers in an uncontrolled manner. Bonding imparts strength and integrity to the web by using heated rolls or hot needles to partially melt the polymer and fuse the fibers together. Fibers that are not highly drawn can be used as the thermally bonded fibers because the increased molecular orientation raises the melting point. In some aspects, the spunbond primary backing component can comprise a sheath-core bicomponent filament. In some aspects, the polymeric core component can have a higher melting point than the polymeric sheath component. In some aspects, the polymeric core component can comprise a polyester, an aliphatic polyamide, a polyphenylene ether, and / or a copolymer or blend thereof. In yet other aspects, the polyester can comprise polyethylene terephthalate, polybutylene terephthalate, or polyphthaloyl terephthalate. In yet other aspects, the polymeric core comprises polyethylene terephthalate. In further aspects, the sheath polymer can comprise a polyamide, a polyethylene, or a polyester. In yet further aspects, the sheath polymer comprises nylon. In still further aspects, the sheath-core primary backing component comprises a polyester as the core component and a nylon as the sheath component. Exemplary sheath-core primary backing components are commercially available from Bonar. In yet other aspects, a polyester nonwoven primary backing is commercially available from Freudenberg.

[0089] In some aspects, multiple fibers exist within the yarn. In others, multiple fibers exist as individual fibers. In some aspects, multiple fibers form clusters. In some aspects, a portion of multiple fibers is exposed on the back side of the main backing component. In still others, a portion of multiple fibers is exposed on the back side of the main backing component in a backing pattern.

[0090] In some aspects, various fibers may comprise polyamides, olefins, or polyesters. As used herein, the term "polyamide" is defined as any long-chain polymer whose connecting functional group is an amide (-CO-NH-) bond. The term polyamide is further defined as including copolymers, terpolymers, and homopolymers, and also includes blends of two or more polyamides. In some aspects, various polyamide fibers comprise one or more of nylon 6, nylon 66, nylon 10, nylon 612, nylon 12, nylon 11, or any combination thereof. In other aspects, various polyamide fibers comprise nylon 6 or nylon 66. In yet another aspect, various polyamide fibers are nylon 6. In yet still another aspect, various polyamide fibers are nylon 66.

[0091] In some respects, many fibers comprise polyester. As used herein, the term "polyester fiber" refers to fibers made from any long-chain synthetic polymer whose fiber-forming material consists of at least 85% by weight of substituted aromatic carboxylic acid esters, including but not limited to substituted terephthalic acid units, p(-RO-CO-C6H4-CO-O-). x And para-substituted hydroxybenzoate unit p(-RO-CO-C6H4-O-) x In some respects, various polyester fibers include polyethylene terephthalate (PET) homopolymers and copolymers, polybutylene terephthalate (PBT) homopolymers and copolymers, etc., including those containing comonomers such as cyclohexanediol, cyclohexanedicarboxylic acid, etc.

[0092] In a further aspect, various fibers may include polyolefin fibers. As defined herein, the term "polyolefin" refers to fibers composed of simple olefins (also known as those having the general formula C...). n H 2n Polyolefins are any kind of polymers produced using olefins as monomers. In some aspects, polyolefins that can be used to produce yarns and fibers include, but are not limited to, polyethylene, polypropylene, both homopolymers and copolymers, poly(1-butene), poly(3-methyl-1-butene), poly(4-methyl-1-pentene), and combinations or mixtures of two or more of the foregoing. In some aspects, various polyolefin fibers contain polyethylene or polypropylene. In other aspects, various polyolefin fibers contain polyethylene. In still other aspects, various polyolefin fibers contain polypropylene.

[0093] In yet further aspects, the plurality of fibers can further comprise natural fibers, acrylics, viscose, rayon, acetate, flax, silk, cotton, wool, or any combination thereof.

[0094] As understood by one of ordinary skill in the art, the plurality of fibers can comprise any type of fiber. For example, and without limitation, the plurality of fibers can comprise staple fibers or bulked continuous filament fibers.

[0095] In an aspect, the greige good can further comprise a pre-coat applied to the back of the composite primary backing component. The pre-coat can be used to enhance tuft bind and lock the plurality of fibers or tufts in place. In some aspects, the pre-coat can provide additional strength to the tufts (so-called tuft bind strength). In yet other aspects, the pre-coat can be used to substantially prevent any subsequent application of the optional binder composition from penetrating through the plurality of fibers (tufts) (between the openings) in the direction of the carpet top surface.

[0096] In some aspects, the pre-coat comprises an aqueous pre-coat material. In some example aspects, the aqueous pre-coat material can be added, for example, as a dispersion or emulsion. In other aspects, the emulsion can be made from various polyolefin materials, such as, for example and without limitation, ethylene acrylic acid (EAA), ethylene vinyl acetate (EVA), polypropylene, or polyethylene (e.g., low density polyethylene (LDPE), linear low density polyethylene (LLDPE), or substantially linear ethylene polymers, or mixtures thereof). In some aspects, the pre-coat can comprise a latex. It is further contemplated that the pre-coat material in the pre-coat can be selected from the group comprising, but not limited to, EVA hot melt, ethylene vinyl acetate (VAE) emulsion, carboxylated styrene-butadiene (XSB) latex copolymer, styrene-butadiene resin (SBR) latex, BDMMA latex, acrylic latex, acrylic copolymer, styrene copolymer, butadiene acrylate copolymer, polyolefin hot melt, polyurethane, polyolefin dispersion and / or emulsion, and any combination thereof.

[0097] In certain aspects, the pre-coat can further comprise one or more flame retardants. Exemplary flame retardants that can be incorporated into the pre-coat include, but are not limited to, organophosphorous flame retardants, red phosphorous, magnesium hydroxide, magnesium dihydroxide, hexabromocyclododecane, bromine-containing flame retardants, brominated aromatic flame retardants, melamine cyanurate, melamine polyphosphate, melamine borate, methylol and its derivatives, silica, calcium carbonate, resorcinol bis(diphenyl phosphate), brominated latex base, antimony trioxide, strontium borate, strontium phosphate, monomeric N-alkoxy hindered amines (NOR HAS), triazines and their derivatives, high aspect ratio talc, phosphate esters, organically modified nanoclays and nanotubes, non-organically modified nanoclays and nanotubes, ammonium polyphosphate, polyphosphoric acid, ammonium salts, triaryl phosphate esters, isopropylated triphenyl phosphate, phosphate esters, magnesium hydroxide, zinc borate, bentonite (alkali-activated nanoclays and nanotubes), organoclays, aluminum trihydrate (ATH), azodicarbonamide, diazene dicarbonamide, azodicarboxylic acid diamide (ADC), triaryl phosphate esters, isopropylated triphenyl phosphate, triazine derivatives, alkali-activated organoclays, and alumina. Any desired amount of flame retardant can be used in the pre-coat, and the amount chosen will depend on the desired carpet application. Such amounts can be readily determined by routine experimentation.

[0098] In still further aspects, the pre-coat can further contain other ingredients. For example, a surfactant can be included. Suitable surfactants can include, for example but not limited to, nonionic, anionic, cationic, and fluorosurfactants. In one aspect, the surfactant is present in an amount of from about 0.01 to about 5 wt% based on the total weight of the emulsion or dispersion. In another aspect, the surfactant is anionic. In a further aspect, the surfactant is cationic. In yet a further aspect, the surfactant is nonionic. In still a further aspect, the surfactant is a fluorosurfactant.

[0099] In another aspect, the pre-coat can further comprise a thickening agent, a defoamer, and / or a dispersion enhancer. In this regard, the thickening agent helps to provide the dispersion with a suitable viscosity. For example, the thickening agent can exemplarily comprise sodium and ammonium salts of polyacrylic acid, and is preferably present in an amount of from about 0.1 to about 5 wt% based on the total weight of the dispersion. The defoamer can be, but is not limited to, a non-silicone defoamer, and is present in an amount of from about 0.01 to about 5.0 wt% based on the total weight of the dispersion. An exemplary dispersion enhancer can be fumed silica used as a compatibilizer for the dispersion. In some aspects, the fumed silica is present in an amount of from about 0.1 to about 0.2 wt% based on the total weight of the dispersion.

[0100] In still another aspect, the pre-coat layer can include one or more fillers. Exemplary and non-limiting fillers that can be incorporated into the pre-coat layer can include calcium carbonate, fly ash, recycled calcium carbonate, aluminum trihydrate, talc, nanoclay, barium sulfate, barite, barite glass fiber, glass powder, cullet, metal powder, alumina, hydrated alumina, clay, magnesium carbonate, calcium sulfate, silica, glass, fumed silica, carbon black, graphite, cement powder, feldspar, nepheline, magnesium oxide, zinc oxide, aluminum silicate, calcium silicate, titanium dioxide, titanate, glass microsphere, chalk, calcium oxide, and any combination thereof. In some aspects, the filler can include about calcium carbonate and aluminum trihydrate. The calcium carbonate and aluminum trihydrate can be present in any ratio suitable for a particular carpet application, such as, but not limited to, the calcium carbonate and aluminum trihydrate can be present in a ratio of about 100: 1 parts, about 100:2 parts, about 100:3 parts, about 100:4 parts, about 100:5 parts, about 100:6 parts, about 100:7 parts, about 100:8 parts, about 100:9 parts, or about 100: 10 parts of calcium carbonate: aluminum trihydrate.

[0101] In some aspects, the carpet compositions described herein can further include an optional secondary backing system, which, when present, is applied to the primary backing backface or optional pre-coat layer. The secondary backing system can include one or more of an adhesive layer, a secondary backing, a reinforcement material, and any combination thereof. In one aspect, the composite material disclosed herein is a secondary backing. Figure 3 Exemplary carpet compositions including a secondary backing system are depicted in FIGS. 1-3. Specifically, Figure 3An exemplary carpet composition 300 is shown. A plurality of fibers 310 present in the yarn are attached or tufted into a primary backing component 320 and extend from a front side 324 of the primary backing component. In one aspect, the primary backing component 320 is a composite material as disclosed herein. A portion of the plurality of fibers are exposed at a back side 326 of the primary backing component in the form of a pile loop 328. An optional precoat layer 330 can be applied to the back side of the primary backing component and the pile loop. An optional adhesive composition 340 is further applied to the precoat layer. A secondary backing material 360 is disposed on an optional reinforcement material 350. As disclosed herein, the secondary backing material 360 can be a composite material as disclosed herein. Also as disclosed herein, the secondary backing material 360 can be a conventional secondary backing material. At least one of the primary backing component 320 and the secondary backing component 360 is a composite material as disclosed herein. In some aspects, a reinforcement material layer 350 can be embedded between the precoat and the secondary backing material. It has been found that the reinforcement material layer can improve the dimensional stability of the carpet composition. Suitable reinforcement materials include dimensionally stable and thermally stable fabrics such as nonwoven or wet-laid fiberglass mat, and woven and nonwoven thermoplastic fabrics (e.g., polypropylene, nylon, and polyester). In some aspects, the reinforcement layer is a fiberglass mat, such as Duraglass available from Johns Manville (about 2.0 ounces per square yard). Alternatively, in other aspects, the reinforcement layer is a fiberglass mat sold by Owens Corning (about 2.0 ounces per square yard).

[0102] In some aspects, when the secondary backing material is a conventional secondary backing material, it can include a thermoplastic polyolefin. In certain aspects, the secondary backing material includes a substantially linear ethylene polymer and a homogeneously branched linear ethylene polymer (i.e., a homogeneously branched ethylene polymer). Homogeneously branched ethylene polymers, including substantially linear ethylene polymers in particular, have low cure temperatures, good adhesion to polypropylene, and low modulus relative to conventional ethylene polymers such as low density polyethylene (LDPE), heterogeneously branched linear low density polyethylene (LLDPE), high density polyethylene (HDPE), and heterogeneously branched ultra low density polyethylene (ULDPE).

[0103] In some aspects, when properly selected substantially linear ethylene polymers or homogeneously branched linear ethylene polymers are used as secondary backing materials, the low flexural modulus of these polymers has advantages in terms of ease of carpet installation and general carpet handling. Substantially linear ethylene polymers, particularly when used as secondary backing materials, exhibit enhanced mechanical adhesion to polypropylene, which improves the consolidation and delamination resistance of various carpet layers and components (i.e., polypropylene fibers, fiber bundles, primary backing components). In some aspects, good abrasion resistance is especially important in commercial carpet cleaning operations, as good abrasion resistance generally can improve the durability of the carpet.

[0104] In certain aspects, secondary backing materials comprising substantially linear ethylene polymers or homogeneously branched linear ethylene polymers can provide a basic fluid and particulate barrier that enhances the sanitary properties of the carpet.

[0105] In some further aspects, the use of secondary backing materials comprising substantially linear ethylene polymers or homogeneously branched linear ethylene polymers can allow for fully recyclable carpet products, particularly where the carpet comprises polypropylene fibers.

[0106] The secondary backing material can comprise a homogeneously branched ethylene polymer. The homogeneously branched ethylene polymer can have a single melting peak between -30°C and 150°C as determined using differential scanning calorimetry. In some aspects, the homogeneously branched ethylene polymer for use in the secondary backing material of the present invention is a substantially linear ethylene polymer characterized by having (a) a melt flow ratio, I 10 / I2> 5.63; (b) a molecular weight distribution, M w / M n， determined by gel permeation chromatography and defined by the following equation: (M w / M n )<(I 10 / I2) - 4.63; (c) gas extrusion rheology such that the critical shear rate at the onset of surface melt fracture of the substantially linear ethylene polymer is at least 50% higher than the critical shear rate at the onset of surface melt fracture of a linear ethylene polymer, wherein the linear ethylene polymer has a homogeneously branched short chain branching distribution without long chain branching, and wherein the substantially linear ethylene polymer and the linear ethylene polymer are both ethylene homopolymers or interpolymers of ethylene with at least one C3-C 20 α-olefin, and have the same I2and M W / M n , and wherein the critical shear rates of the substantially linear ethylene polymer and the linear ethylene polymer are each measured using a gas extrusion rheometer at the same melt temperature; and (d) separate differential scanning calorimetry DSC, melting peak between -30°C and 150°C.

[0107] The critical shear rate associated with melt fracture and other rheological properties such as "rheological processing index" (PI) are determined using a gas extrusion rheometer (GER). The gas extrusion rheometer is described by M. Shida, R. N. Shroff, and L. V. Cancio, Polymer Engineering Science, Vol. 17, No. 11, p. 770 (1977), and by John Dealy in "Rheometers for Molten Plastics" pp. 97-99 (1982) (published by Van Nostrand Reinhold Co.), the disclosures of which are incorporated herein by reference. The GER experiments are conducted using a 20: 1 L / D die with a 0.0754 mm diameter, approximately 180° entry angle at a temperature of 190 °C under nitrogen pressure of about 250 to about 5500 psig (about 1.7 to about 37.4 MPa). For substantially linear ethylene polymers used herein, the PI is the apparent viscosity (in kpoise) of the material measured by the GER at an apparent shear stress of 2.15 x 10 6 dyne / cm 2 (2.19 x 10 4 kg / m 2 ) at 190 °C. In certain aspects, the secondary backing material can comprise a substantially linear ethylene polymer having a PI in the range of 0.01 kpoise to 50 kpoise, 15 kpoise or less. The substantially linear ethylene polymers used herein also have a PI less than or equal to 70% of the PI of a linear ethylene polymer (either a Ziegler polymerized polymer described by Elston in U.S. Patent No. 3,645,992 or a homogeneously branched linear polymer) having an I2and Mw w / M n , each of which is within ten percent of the substantially linear ethylene polymer.

[0108] In some aspects, the homogeneously branched ethylene polymers for use in the present application can be characterized by a single DSC melting peak. The single melting peak is determined using a differential scanning calorimeter standardized with indium and deionized water. The method involves a sample size of 5-7 mg, a "first heat" to about 140 °C for 4 minutes, a cool down to -30 °C at 10 °C / minute, a hold for 3 minutes, and then a heat to 150 °C at 10 °C / minute as a "second heat". The single melting peak is taken from the heat flow versus temperature curve of the "second heat". The total heat of fusion of the polymer is calculated from the area under the curve.

[0109] In further aspects, for polymers having a density of about 0.875 g / cc to about 0.910 g / cc, the single melting peak can exhibit a "shoulder" or "hump" on the low melting point side, accounting for less than about 12%, typically less than about 9%, and more typically less than about 6% of the total heat of fusion of the polymer, depending on the sensitivity of the equipment. For other homogeneously branched polymers, such as Exact TM Resins, such artifacts can be observed and distinguished on the basis of the slope of the single melting peak passing through the melting region of the artifact. Such artifacts occur within 34°C, typically within 27°C, and more typically within 20°C of the melting point of the single melting peak. The heat of fusion attributable to the artifact can be separately determined by the specific integration of the area under the heat flow versus temperature curve.

[0110] In certain aspects, the substantially linear ethylene polymers and homogeneously linear ethylene polymers used in the present application have a molecular weight distribution (M w / M n ) of about 1.8 to about 2.8. It is known that substantially linear ethylene polymers have excellent processing properties despite having a relatively narrow molecular weight distribution. Unlike homogeneously and heterogeneously branched linear ethylene polymers, the melt flow ratio (I 10 / I2) of substantially linear ethylene polymers can vary substantially independently of their molecular weight distribution M w / M n .

[0111] In some aspects, the secondary backing material comprising a homogeneously branched ethylene polymer includes an interpolymer of ethylene and at least one alpha-olefin prepared by solution, gas phase, or slurry polymerization processes, or combinations thereof. In some aspects, the alpha-olefin is represented by the general formula:

[0112] CH2=CHR

[0113] where R is a hydrocarbyl radical. Further, R can be a hydrocarbyl radical having from 1 to 20 carbon atoms, thus the general formula includes C3-C 20Alpha-olefins. In other aspects, alpha-olefins used as comonomers include propylene, 1-butene, 1-iso-butene, 1-pentene, 1-hexene, 4-methyl-1-pentene, 1-heptene, and 1-octene, as well as other comonomer types such as styrene, halogenated or alkyl-substituted styrene, tetrafluoroethylene, vinylbenzocyclobutene, 1,4-hexadiene, 1,7-octadiene, and cyclic olefins, such as cyclopentene, cyclohexene, and cyclooctene. In certain aspects, the comonomer will be 1-butene, 1-pentene, 4-methyl-1-pentene, 1-hexene, 1-heptene, 1-octene, or mixtures thereof, as the secondary backing material composed of higher alpha-olefins will have particularly improved toughness. In yet other aspects, the comonomer will be 1-octene, and the ethylene polymer will be prepared using a solution process.

[0114] In certain aspects, the substantially linear ethylene polymers or homogeneously branched linear ethylene polymers have a density of no more than about 0.92 g / cc, and typically in the range of about 0.85 g / cc to about 0.92 g / cc, about 0.86 g / cc to about 0.91 g / cc, and about 0.86 g / cc to about 0.90 g / cc, as measured according to ASTM D-792.

[0115] In yet further aspects, the molecular weight of the homogeneously branched linear ethylene polymers or substantially linear ethylene polymers can be characterized using melt index measurements according to ASTM D-1238, Condition 190°C / 2.16 kg (formerly known as "Condition (E)", also referred to as I2). Melt index is inversely proportional to the molecular weight of the polymer. Thus, the higher the molecular weight, the lower the melt index, although this relationship is not linear. The homogeneously branched linear ethylene polymers or substantially linear ethylene polymers typically have a melt index of about 1 gram / 10 minutes (g / 10 min) to about 500 g / 10 min, about 2 g / 10 min to about 300 g / 10 min, about 5 g / 10 min to about 100 g / 10 min, about 10 g / 10 min to about 50 g / 10 min, and about 25 to about 35 g / 10 min.

[0116] In some other aspects, additional measurements can be used to characterize the molecular weight of the homogeneously linear ethylene polymers or substantially linear ethylene polymers, and can be made using melt index measurements according to ASTM D-1238, Condition 190°C / 10 kg (formerly known as "Condition (N)", also referred to as I 10 ). I 10 The ratio of the I 10 / I2melt index terms is the melt flow ratio, and is expressed as I 10 / I2. For substantially linear ethylene polymers, the I 10The higher the I2 / I1 ratio, the more long chain branching in the polymer. The I2 / I1 ratio for substantially linear ethylene polymers is typically less than about 6.3. 10 The I2 / I1 ratio is at least about 6.5, at least about 7, or at least about 8. The I2 / I1 ratio for homogeneously branched linear ethylene polymers is typically less than about 6.3. 10 The I2 / I1 ratio is at least about 6.5, at least about 7, or at least about 8. The I2 / I1 ratio for homogeneously branched linear ethylene polymers is typically less than about 6.3.

[0117] In some aspects, the ethylene polymers can have a relatively low modulus. That is, the ethylene polymers can be characterized as having a 2% secant modulus of less than about 24,000 psi (163.3 MPa), less than about 19,000 psi (129.3 MPa), and less than about 14,000 psi (95.2 MPa), as measured according to ASTM D790.

[0118] In certain aspects, the ethylene polymers described herein are substantially amorphous or completely amorphous. That is, the ethylene polymers are characterized as having a percent crystallinity of less than about 40%, less than about 30%, less than about 20%, and less than about 10%, as measured by a differential scanning calorimeter using the following equation:

[0119] Percent Crystallinity = (H f / 292) x 100, where H f is the heat of fusion in Joules / gram.

[0120] In other aspects, the homogeneously branched ethylene polymers (HBEP) can be used alone or can be blended or mixed with one or more synthetic or natural polymeric materials. In some aspects, the polymers used for blending or mixing with the homogeneously branched ethylene polymers used in the present invention include, but are not limited to, another homogeneously branched ethylene polymer, a low density polyethylene, a heterogeneously branched LLDPE, a heterogeneously branched ULDPE, a medium density polyethylene, a high density polyethylene, a grafted polyethylene (e.g., a maleic anhydride extrusion grafted heterogeneously branched linear oligoethylene or a maleic anhydride extrusion grafted homogeneously branched ultra low density polyethylene), an ethylene acrylic acid copolymer, an ethylene vinyl acetate copolymer, an ethylene ethyl acrylate copolymer, a polystyrene, a polypropylene, a polyester, a polyurethane, a polybutene, a polyamide, a polycarbonate, a rubber, an ethylene propylene polymer, an ethylene styrene polymer, a styrene block copolymer, and a vulcanized rubber.

[0121] In further aspects, the secondary backing material can comprise a blend of at least two polyethylenes, where the polyethylenes can comprise a homogeneously branched ethylene polymer (HBEP) or a substantially linear ethylene polymer (SLEP) or mixtures thereof. In other aspects, the secondary backing material can comprise a blend of at least three or four or more polyethylenes, where the polyethylenes comprise a homogeneously branched ethylene polymer (HBEP) or a substantially linear ethylene polymer (SLEP) or mixtures thereof. Still further, the secondary backing material can comprise a polyethylene comprising at least about 80 wt% of at least one (or two or more) HBEP or SLEP, including exemplary values of about 85%, 90%, 95%, 97%, 98%, or about 99% by weight of the polyethylene, where any value can constitute an upper or lower limit, as the case can be, by weight of the polyethylene.

[0122] In aspects using a blend of at least two (or three or more) polyethylenes, the amount of each polyethylene can vary individually, for example, in amounts of about 1%, 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, 97%, or about 98% by weight of the total blend, where any value can be used for an individual component and any value can be used as an upper or lower limit, as the case can be.

[0123] The density of the polyethylene components in the blend can be about 0.860, 0.870, 0.880, 0.885, 0.890, 0.895, 0.900, 0.905, or about 0.910 g / cc. Further, the density can be within a range derived from the above values, where any of the above values can be used as an upper or lower limit, as the case can be.

[0124] The actual blending or mixing of the various polymers can be conveniently accomplished by any technique known in the art, including but not limited to melt extrusion compounding, dry blending, roll milling, melt mixing, such as in Banbury mixers and multi-reactor polymerization. In some aspects, the blend or mixture includes a homogeneously branched ethylene polymer and a heterogeneously branched ethylene alpha-olefin interpolymer, where the alpha-olefin is a C3-C8 alpha-olefin prepared using two reactors operating in parallel or in series, each employing a different catalyst system.

[0125] In another aspect, the secondary backing material can comprise a modified homogeneously branched ethylene polymer. Specifically, in certain aspects of the present application, at least one homogeneously branched ethylene polymer that can be present in the secondary backing material can be modified by the addition of at least one tackifying polymer additive. Suitable tackifying polymer additives include, for example, but are not limited to, polymer products consisting of: (1) one or more ethylenically unsaturated carboxylic acids, anhydrides, alkyl esters and half esters, such as acrylic acid, methacrylic acid, maleic acid, maleic anhydride, itaconic acid, fumaric acid, crotonic acid and citraconic acid, citraconic anhydride, succinic acid, succinic anhydride, dimethyl maleate and diethyl maleate; esters of ethylenically unsaturated carboxylic acids, such as ethyl acrylate, methyl methacrylate, ethyl methacrylate, methyl acrylate, isobutyl acrylate and methyl fumarate; unsaturated esters of carboxylic acids, such as vinyl acetate, vinyl propionate and vinyl benzoate; and ethylenically unsaturated amides and nitriles, such as acrylamide, acrylonitrile, methacrylonitrile and fumaronitrile; and (2) one or more ethylenically unsaturated hydrocarbon monomers, such as aliphatic alpha-olefin monomers, such as ethylene, propylene, 1-butene and isobutylene; conjugated dienes, such as butadiene and isoprene; and monovinylidene aromatic carbocyclic monomers, such as styrene, alpha-methyl styrene, toluene and t-butyl styrene.

[0126] Modified homogeneously branched ethylene polymers for use in the secondary backing material can be readily prepared by known techniques, such as, for example, by copolymerization or by a polymerization step followed by a chemical or extrusion grafting step. Suitable grafting techniques are described in U.S. Patent Nos. 4,762,890; 4,927,888; 4,230,830; 3,873,643; and 3,882,194, the entire disclosures of which are incorporated herein by reference.

[0127] In some aspects, the tackifying polymer additive for use in the present application can comprise a maleic anhydride graft, wherein the maleic anhydride is grafted onto an ethylene polymer at a concentration of about 0.1 to about 5.0 wt.%, about 0.5 to about 1.5 wt.%. The presence of the ethylene polymer / maleic anhydride graft as a tackifying polymer additive in the present application can improve the extrusion performance and operating window of the homogeneously branched ethylene polymer applied as a secondary backing material, particularly when used in combination with polar polymers, such as, for example, but not limited to, nylon and polyester face carpets. This improvement relates to significantly higher abrasion resistance and tuft bind strength. In one exemplary aspect, the composition used to form the maleic anhydride graft is Engage® 8200, available from Dow Chemicals. GR 204.

[0128] In further aspects, the ethylene polymers used as the graft base polymer include low density polyethylene (LDPE), high density polyethylene (HDPE), heterogeneously branched linear low density polyethylene (LLDPE), homogeneously branched linear ethylene polymers, and substantially linear ethylene polymers. In some aspects, the base ethylene polymer has a polymer density greater than or equal to about 0.86 g / cc, 0.87 g / cc, 0.88 g / cc, 0.89 g / cc, 0.90 g / cc, 0.91 g / cc, 0.92 g / cc, 0.93 g / cc, or greater than or equal to about 0.94 g / cc. In still other aspects, substantially linear ethylene polymers and high density polyethylene are used as the base ethylene polymer.

[0129] In some aspects, the secondary backing material can be extruded or coated by any other technique known in the art. In some aspects, the secondary backing material of the present application can optionally include exemplary additives such as blowing agents, pH control agents, flame retardants, fillers, tackifiers, wetting agents, dispersants, antimicrobial agents, lubricants, dyes, antioxidants, and the like, as are well known to those skilled in the art without any loss of characteristic properties.

[0130] In one aspect, the secondary backing material can further comprise one or more flame retardants sufficient to ensure that the carpet structure meets the radiant flux flooring test requirements according to the ASTM-E648 test procedure. Specifically, according to certain aspects, the carpet compositions of the present application exhibit a critical radiant flux of greater than 0.45 Watts / cm 2 , as measured according to ASTM-E648. According to other aspects of the present application, the carpet compositions described herein can exhibit a critical radiant flux of Class 2, ranging from 0.22 to 0.44 Watts / cm 2 , as measured according to ASTM-E648. In still further aspects, the carpet compositions of the present application can exhibit a critical radiant flux of less than 0.22 Watts / cm 2 , as measured according to ASTM-E648.

[0131] Exemplary flame retardants that can be incorporated into the secondary backing materials of the present application include, but are not limited to, organophosphorous flame retardants, red phosphorous, magnesium hydroxide, magnesium dihydroxide, hexabromocyclododecane, bromine-containing flame retardants, brominated aromatic flame retardants, melamine cyanurate, melamine polyphosphate, melamine borate, methylol and its derivatives, silica, calcium carbonate, resorcinol bis(diphenyl phosphate), brominated latex base, antimony trioxide, strontium borate, strontium phosphate, monomeric N-alkoxy hindered amines (NOR HAS), triazines and their derivatives, high aspect ratio talc, phosphate esters, organically modified nanoclays and nanotubes, non-organically modified nanoclays and nanotubes, ammonium polyphosphate, polyphosphoric acid, ammonium salts, triaryl phosphate esters, isopropylated triphenyl phosphate, phosphate esters, magnesium hydroxide, zinc borate, bentonite (alkali-activated nanoclays and nanotubes), organoclays, aluminum trihydrate (ATH), azodicarbonamide, diazene dicarbonamide, azodicarboxylic diamide (ADC), triaryl phosphate esters, isopropylated triphenyl phosphate, triazine derivatives, alkali-activated organoclays, and alumina. Any desired amount of flame retardant can be used in the secondary backing materials of the present application, and the selection of the amount will depend in part on the particular flame retardant used and the desired carpet application. Such amounts can be readily determined through routine experimentation.

[0132] Exemplary and non-limiting fillers that can be incorporated into the secondary backing material of the present application can include calcium carbonate, fly ash, recycled calcium carbonate, aluminum trihydrate, talc, nanoclay, barium sulfate, barite, barite glass fiber, glass powder, cullet, metal powder, alumina, hydrated alumina, clay, magnesium carbonate, calcium sulfate, silica, glass, fumed silica, carbon black, graphite, cement powder, feldspar, nepheline, magnesium oxide, zinc oxide, aluminum silicate, calcium silicate, titanium dioxide, titanate, glass microsphere, chalk, calcium oxide, and any combination thereof. In one aspect, the secondary backing material comprises inorganic fillers having a high heat content. In some aspects, the fillers exhibit a relatively high heat content. Examples of such fillers include, but are not limited to, calcium carbonate, aluminum trihydrate, talc, and barite. Exemplary high heat content fillers allow the extrudate to remain at elevated temperatures for longer periods of time, with the beneficial result of providing enhanced encapsulation and permeation. In this regard, the high heat content fillers should be ground or precipitated to a size that can be readily incorporated into the extrusion coating melt stream. Exemplary non-limiting particle sizes of the inorganic filler material can include a particle size ranging from about 1 to about 50 microns. Still further, it should also be appreciated that the filler component can be present in any desired amount. However, in one exemplary aspect, the filler is present in an amount ranging from about 10 wt.% to about 90 wt.%, including exemplary amounts of about 15 wt.%, 20 wt.%, 25 wt.%, 30 wt.%, 35 wt.%, 40 wt.%, 45 wt.%, 50 wt.%, 55 wt.%, 60 wt.%, 65 wt.%, 70 wt.%, 75 wt.%, 80 wt.%, and about 85 wt.%, based on the total weight of the secondary backing material. Still further, the filler can be present in an amount within any range derived from any two of the above weight percentages.

[0133] In still another aspect, the secondary backing material can further comprise one or more tackifying additives. The tackifying agent may, for example, be based on tall oil or rosin, or, alternatively, can be an aliphatic or aliphatic aromatic blending resin. As the tackifying agent is an optional component, when present, the amount of tackifying agent can range from greater than 0 wt.% to even more than about 50 wt.% of the secondary backing material. For example, in one aspect, the amount of tackifying agent can range from about 5 wt.% to about 45 wt.%. In still another aspect, the amount of tackifying agent can range from about 10 wt.% to about 20 wt.%.

[0134] In other aspects, the carpet composition may further include an additional backing. In some aspects, the additional backing may comprise a woven material. In still other aspects, the backing may comprise tape-tape yarn or tape-spun yarn. In some aspects, the additional backing material is a tape-yape type woven material. In some exemplary aspects, the material used for the additional backing may be a conventional material, such as, but not limited to, woven polypropylene fabrics sold by Propex. Such a backing may comprise a leno weave material in which polypropylene tapes extend in one direction and polypropylene yarns extend in another direction. In other aspects, the backing material that can be used in the present invention is a woven polypropylene fabric having monofilaments extending in both directions. A suitable example of such a material is the material of model S8880 manufactured by Shaw Industries. In a further aspect, the additional backing material is a material referred to as fiber lock weave or “FLW”. FLW is a material comprising needle-punched fibers. Sometimes, FLW is used as the main backing component of carpets with a lighter pile weight. In some aspects, the additional backing can be a woven needle-punched polypropylene fabric, such as that manufactured by Shaw Industries. In this exemplary aspect, the material is reinforced by needle-punching approximately 1.5 ounces / yard square of polypropylene or polyethylene terephthalate fibers to one side, and the total basic weight is approximately 3.5 ounces / yard square. This needle-punched fabric can be laminated to embed the polypropylene fibers into the backing layer. Further still, other materials can be used for additional backing, such as, but not limited to, polyurethane foam or other padding materials laminated to the back of the carpet if an integral pad is required. Such backings can be used for wide carpets.

[0135] In some aspects, the carpet compositions disclosed herein comprise carpet tiles, wide-width carpets, rugs, or artificial turf. In other aspects, the carpet compositions disclosed herein are carpet tiles, wide-width carpets, rugs, or synthetic turf.

[0136] C. Methods for manufacturing composite materials and carpet compositions

[0137] In one aspect, this paper discloses a method for preparing the composite material disclosed herein.

[0138] In an aspect, a method of making a composite material is disclosed, comprising the step of laminating: a) a continuous or discontinuous first polymeric film having a front side and a back side, wherein the first polymeric film comprises a first polymeric blend comprising a first polymer and a second polymer, wherein the first polymer is immiscible with the second polymer; b) a first nonwoven having a front side and a back side, wherein the front side of the first nonwoven contacts the back side of the first polymeric film; c) a continuous or discontinuous second polymeric film having a front side and a back side, wherein the second polymeric film comprises a second polymeric blend comprising a third polymer and a fourth polymer, wherein the third polymer is immiscible with the fourth polymer, wherein the front side of the second polymeric film contacts the back side of the first nonwoven; and d) a second nonwoven having a front side and a back side, wherein the front side of the second nonwoven contacts the back side of the second polymeric film, thereby making a composite material. In an aspect, the composite material is a composite material disclosed herein.

[0139] In an aspect, the laminating step can be accomplished in a single step. Thus, the continuous or discontinuous first polymeric film, the first nonwoven, the continuous or discontinuous second polymeric film, and the second nonwoven are introduced into a device simultaneously, which laminates the continuous or discontinuous first polymeric film, the first nonwoven, the continuous or discontinuous second polymeric film, and the second nonwoven in a single step.

[0140] In an aspect, the laminating step can be accomplished in multiple laminating steps. For example, the continuous or discontinuous first polymeric film and the first nonwoven can be laminated in one step, and the continuous or discontinuous second polymeric film and the second nonwoven can be laminated in another step. The laminated first polymeric film and first nonwoven can then be laminated together with the laminated second polymeric film and second nonwoven.

[0141] In still further aspects, methods of making a carpet composition comprising a composite material of the present invention are disclosed herein.

[0142] The face of a tufted carpet can be made in three ways. First, for loop pile carpets, the yarn loops formed during the tufting process remain intact. Second, for cut pile carpets, the yarn loops are cut during or after tufting to produce a pile of single yarn ends rather than loops of yarn. Third, some carpet styles include both loop and cut pile. One variety of this hybrid carpet is called tip-sheared carpet, in which loops of different lengths are tufted and then the carpet is sheared to a certain height to produce a mix of uncut, partially cut, and fully cut loops. Alternatively, the tufting machine can be configured to cut only some of the loops, leaving a pattern of cut and uncut loops. Whether loop pile, cut pile, or hybrid, the yarn on the back of the primary backing component contains tight, unextended loops. Without the use of adhesive backing material or secondary backing material, the combination of tufted yarn and primary backing component is referred to in the carpet industry as a raw tufted carpet or a greige. The greige becomes a finished tufted carpet (if present, on the back of the primary backing material) to which a secondary backing material or any other additional backing is applied. In aspects of the present invention, the greige becomes a finished tufted carpet to which a secondary backing material is applied. Finished tufted carpets can be made into carpet tiles that are typically 6 or 12 feet wide or into wide-width carpets that are rolled. In some other aspects, wide-width carpets can be made into 13'6" and 15' foot wide rolls.

[0143] In another aspect, any conventional tufting or needle punch equipment and / or stitching method can be used to manufacture the carpet composition of the present invention. Likewise, it does not matter whether the tufted yarn loops remain cut to produce loops; are cut to produce cut pile; or are cut, partially cut, and uncut to form a face structure known as tip-sheared. After the yarn is tufted or needle punched into the primary backing component, the greige can be conventionally rolled and held with the back of the primary backing component facing outward until it is transferred to the backing line.

[0144] The optional pre-coat composition can be applied to the carpet composition as a pre-coat composition layer in a variety of ways. For example, the pre-coat can be applied directly, such as with a roll applicator or doctor blade. Alternatively, the pre-coat composition can be applied indirectly, such as with a pan applicator. The amount of pre-coat applied and the concentration of particles in the pre-coat can vary depending on the processing and product parameters desired. In some aspects, the pre-coat composition layer is present in the carpet composition in an amount of about 17 ounces per square yard or less, about 16 ounces per square yard or less, about 15 ounces per square yard or less, about 14 ounces per square yard or less, about 13 ounces per square yard or less, or about 12 ounces per square yard or less.

[0145] After the pre-coat composition layer is applied, the back of the primary backing can be heated to dry, melt, and / or cure the composition. As a result, the yarn loops are able to at least partially secure to the primary backing. Preferably, the heat is applied by passing the product through an oven.

[0146] After treatment with the optional pre-coat composition, an additional backing material can be applied thereover. The additional backing can be applied by various methods, with the preferred method involving the use of an extruded sheet of thermoplastic material. In some aspects, a molten thermoplastic material is extruded through a die to produce a sheet that is as wide as the carpet composition. The molten extruded sheet is applied to the backside of the primary carpet backing. Because the sheet is molten, the sheet will conform to the shape of the yarn loops and further serve to encapsulate and secure the pile in the primary backing.

[0147] Exemplary extrusion coating configurations can include, but are not limited to, single layer T-die coating, single lip die co-extrusion coating, dual lip die co-extrusion coating, hanger die coating, and multi-stage extrusion coating. Preferably, the extrusion coating equipment is configured to apply a total coating weight of about 4 to about 60 ounces per square yard (OSY), including exemplary amounts of 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, and 55 ounces per square yard (OSY), as well as any coating weight ranges derived from these values. To this end, it will be appreciated that the desired coating weight of the extrusion coating depends at least in part on the amount of any flame retardant or inorganic filler in the extrudate.

[0148] The melt temperature of the extrusion coating is primarily dependent on the specific composition of the backing composition being extruded. When extruded using the secondary backing compositions described herein, the extrusion coating melt temperature can be greater than about 300 °F, 310 °F, 320 °F, 330 °F, 340 °F, 350 °F, 360 °F, 370 °F, 380 °F, 390 °F, 400 °F, 410 °F, 420 °F, 430 °F, 440 °F, 450 °F, 460 °F, 470 °F, 480 °F, 490 °F, 500 °F, 510 °F, 520 °F, 530 °F, 540 °F, 550 °F, 560 °F, 570 °F, 580 °F, 590 °F, 600 °F, 610 °F, 620 °F, 630 °F, 640 °F, 650 °F, 660 °F, 670 °F, 680 °F, 690 °F, 700 °F, 710 °F, 720 °F, 730 °F, 740 °F, 750 °F, 760 °F, 770 °F, 780 °F, 790 °F, 800 °F, 810 °F, 820 °F, 830 °F, 840 °F, 850 °F, 860 °F, 870 °F, 880 °F, 890 °F, 900 °F, 910 °F, 920 °F, 930 °F, 940 °F, 950 °F, 960 °F, 970 °F, 980 °F, 990 °F, 1000 °F, 1010 °F, 1020 °F, 1030 °F, 1040 °F, 1050 °F, 1060 °F, 1070 °F, 1080 °F, 1090 °F, 1100 °F, 1110 °F, 1120 °F, 1130 °F, 1140 °F, 1150 °F, 1160 °F, 1170 °F, 1180 °F, 1190 °F, 1200 °F, 1210 °F, 1220 °F, 1230 °F, 1240 °F, 1250 °F, 1260 °F, 1270 °F, 1280 °F, 1290 °F, 1300 °F, 1310 °F, 1320 °F, 1330 °F, 1340 °F, 1350 °F, 1360 °F, 1370 °F, 1380 °F, 1390 °F, 1400 °F, 1410 °F, 1420 °F, 1430 °F, 1440 °F, 1450 °F, 1460 °F, 1470 °F, 1480 °F, 1490 °F, 1500 °F, 1510 °F, 1520 °F, 1530 °F, 1540 °F, 1550 °F, 1560 °F, 1570 °F, 1580 °F, 1590 °F, 1600 °F, 1610 °F, 1620 °F, 1630 °F, 1640 °F, 1650 °F, 1660 °F, 1670 °F, 1680 °F, 1690 °F, 1700 °F, 1710 °F, 1720 °F, 1730 °F, 1740 °F, 1750 °F, 1760 °F, 1770 °F, 1780 °F, 1790 °F, 1800 °F, 1810 °F, 1820 °F, 1830 °F, 1840 °F, 1850 °F, 1860 °F, 1870 °F, 1880 °F, 1890 °F, 1900 °F, 1910 °F, 1920 °F, 1930 °F, 1940 °F, 1950 °F, 1960 °F, 1970 °F, 1980 °F, 1990 °F, or 2000 °F. and in some aspects, in the range of In another aspect, the melt temperature can be in the range of Alternatively, the melt temperature can be in the range of

[0149] D. Aspects

[0150] With the composite materials and carpet compositions and methods described, and variations thereof, in mind certain more particularly described aspects of the application are described below. These specifically recited aspects, however, should not be construed as having any limiting effect on any different claims encompassing different or more general teachings recited herein, or that the “particular” aspects are somehow limited in a manner other than the inherent meaning of the language literally used.

[0151] ​​​​Aspect 1 : A composite material comprising: (a) a continuous or discontinuous first polymeric film having a front side and a back side, wherein the first polymeric film comprises a first polymeric blend comprising a first polymer and a second polymer, wherein the first polymer is immiscible with the second polymer; (b) a first nonwoven having a front side and a back side, wherein the front side of the first nonwoven contacts the back side of the first polymeric film; (c) a continuous or discontinuous second polymeric film having a front side and a back side, wherein the second polymeric film comprises a second polymeric blend comprising a third polymer and a fourth polymer, wherein the third polymer is immiscible with the fourth polymer, wherein the front side of the second polymeric film contacts the back side of the first nonwoven; and (d) a second nonwoven having a front side and a back side, wherein the front side of the second nonwoven contacts the back side of the second polymeric film.

[0152] Aspect 2: A composite material comprising: (a) a continuous or discontinuous first polymeric film having a front side and a back side, wherein the first polymeric film comprises a first polymeric blend comprising a first polymer and a second polymer, wherein the first polymer is immiscible with the second polymer; (b) a first nonwoven having a front side and a back side; (c) a continuous or discontinuous second polymeric film having a front side and a back side, wherein the second polymeric film comprises a second polymeric blend comprising a third polymer and a fourth polymer, wherein the third polymer is immiscible with the fourth polymer; and (d) a second nonwoven having a front side and a back side.

[0153] Aspect 3: The composite material of Aspect 2, wherein the front side of the second polymeric film contacts the back side of the first polymeric film.

[0154] Aspect 4: The composite material of Aspect 2 or 3, wherein the front side of the first polymeric film contacts the back side of the first nonwoven.

[0155] Aspect 5: The composite material of any one of Aspects 2 to 4, wherein the front side of the second nonwoven contacts the back side of the first polymeric film.

[0156] Aspect 6: The composite material of any one of Aspects 2 to 4, wherein the front side of the first nonwoven contacts the back side of the second nonwoven.

[0157] Aspect 7: The composite material of Aspect 3, wherein the front side of the first nonwoven contacts the back side of the second polymeric film.

[0158] Aspect 8: The composite material of Aspect 3 or 7, wherein the face side of the second nonwoven fabric contacts the back side of the first nonwoven fabric.

[0159] Aspect 9: The composite material of Aspect 2, wherein the face side of the first nonwoven fabric contacts the back side of the first polymeric film.

[0160] Aspect 10: The composite material of Aspect 2 or 9, wherein the face side of the second nonwoven fabric contacts the back side of the first nonwoven fabric.

[0161] Aspect 11 : The composite material of any one of Aspects 2 or 9 to 10, wherein the face side of the second polymeric film contacts the back side of the second nonwoven fabric.

[0162] Aspect 12: The composite material of Aspect 2, wherein the face side of the first polymeric film contacts the back side of the first nonwoven fabric.

[0163] Aspect 13: The composite material of Aspect 2 or 12, wherein the face side of the second nonwoven fabric contacts the back side of the first polymeric film.

[0164] Aspect 14: The composite material of any one of Aspects 2, 12, or 13, wherein the face side of the second polymeric film contacts the back side of the second nonwoven fabric.

[0165] Aspect 15: A composite material comprising: (a) a continuous or discontinuous first polymeric film having a face side and a back side, wherein the first polymeric film comprises a first polymeric blend comprising a first polymer and a second polymer, wherein the first polymer is immiscible with the second polymer; (b) a first nonwoven fabric having a face side and a back side; and (c) a continuous or discontinuous second polymeric film having a face side and a back side, wherein the second polymeric film comprises a second polymeric blend comprising a third polymer and a fourth polymer, wherein the third polymer is immiscible with the fourth polymer.

[0166] Aspect 16: The composite material of Aspect 15, wherein the face side of the second polymeric film contacts the back side of the first polymeric film.

[0167] Aspect 17: The composite material of Aspect 15 or 16, wherein the face side of the first polymeric film contacts the back side of the first nonwoven fabric.

[0168] Aspect 18: The composite material of Aspect 15 or 16, wherein the face side of the first nonwoven fabric contacts the back side of the second polymeric film.

[0169] Aspect 19: The composite material of aspect 15, wherein the face side of the first nonwoven fabric contacts the back side of the first polymeric film.

[0170] Aspect 20: The composite material of aspect 15 or 19, wherein the face side of the second polymeric film contacts the back side of the first nonwoven fabric.

[0171] Aspect 21 : The composite material of any one of aspects 1 to 20, wherein the composite material comprises a continuous first polymeric film.

[0172] Aspect 22: The composite material of any one of aspects 1 to 21, wherein the composite material comprises a continuous second polymeric film.

[0173] Aspect 23: The composite material of any one of aspects 1 to 22, wherein the composite material comprises a continuous first polymeric film and a continuous second polymeric film.

[0174] Aspect 24: The composite material of any one of aspects 1 to 23, wherein the composite material comprises a non-continuous first polymeric film.

[0175] Aspect 25: The composite material of any one of aspects 1 to 24, wherein the composite material comprises a non-continuous second polymeric film.

[0176] Aspect 26: The composite material of any one of aspects 1 to 25, wherein the composite material comprises a non-continuous first polymeric film and a non-continuous second polymeric film.

[0177] Aspect 27: The composite material of any one of aspects 1 to 26, wherein the composite material comprises a continuous first polymeric film and a non-continuous second polymeric film.

[0178] Aspect 28: The composite material of any one of aspects 1 to 27, wherein the composite material comprises a non-continuous first polymeric film and a continuous second polymeric film.

[0179] Aspect 29: The composite material of any one of aspects 1 to 28, wherein the composite material is a laminated composite material.

[0180] Aspect 30: The composite material of any one of aspects 1 to 29, wherein the first polymeric film is an extruded film.

[0181] Aspect 31 : The composite material of any one of aspects 1 to 30, wherein the second polymeric film is an extruded film.

[0182] Aspect 32: The composite material of any one of aspects 1 to 31, wherein the first polymeric film and the second polymeric film are extruded in the same direction.

[0183] Aspect 33: The composite material of any one of aspects 1 to 31, wherein the first polymeric film and the second polymeric film are extruded in directions that cross each other.

[0184] Aspect 34: The composite material of any one of aspects 1 to 33, wherein the composite material has a front side and a back side, wherein the front side of the composite material is the front side of the first polymeric film, and wherein the back side of the composite material is the back side of the second nonwoven.

[0185] Aspect 35: The composite material of any one of aspects 1 to 34, wherein the first polymeric blend and the second polymeric blend are substantially the same.

[0186] Aspect 36: The composite material of any one of aspects 1 to 35, wherein the first polymeric blend comprises from about 1 wt% to about 99 wt% of the first polymer and from about 99 wt% to about 1 wt% of the second polymer.

[0187] Aspect 37: The composite material of any one of aspects 1 to 36, wherein the first polymeric blend comprises from about 5 wt% to about 50 wt% of the first polymer and from about 95 wt% to about 50 wt% of the second polymer.

[0188] Aspect 38: The composite material of any one of aspects 1 to 37, wherein the first polymeric blend comprises from about 20 wt% to about 30 wt% of the first polymer and from about 80 wt% to about 70 wt% of the second polymer.

[0189] Aspect 39: The composite material of any one of aspects 1 to 38, wherein the second polymeric blend comprises from about 1 wt% to about 99 wt% of the third polymer and from about 99 wt% to about 1 wt% of the fourth polymer.

[0190] Aspect 40: The composite material of any one of aspects 1 to 39, wherein the second polymeric blend comprises from about 5 wt% to about 50 wt% of the third polymer and from about 95 wt% to about 50 wt% of the fourth polymer.

[0191] Aspect 41: The composite material of any one of aspects 1 to 40, wherein the second polymeric blend comprises from about 20 wt% to about 30 wt% of the third polymer and from about 80 wt% to about 70 wt% of the fourth polymer.

[0192] Aspect 42: The composite material of any one of aspects 1-41, wherein the first polymeric film comprises two or more alternating layers of the first polymer and the second polymer.

[0193] Aspect 43: The composite material of any one of aspects 1-42, wherein the second polymeric film comprises two or more alternating layers of the third polymer and the fourth polymer.

[0194] Aspect 44: The composite material of any one of aspects 1-43, wherein the first polymeric film comprises filaments of the first polymer within a continuous phase of the second polymer.

[0195] Aspect 45: The composite material of any one of aspects 1-44, wherein the second polymeric film comprises filaments of the third polymer within a continuous phase of the fourth polymer.

[0196] Aspect 46: The composite material of any one of aspects 1-45, wherein the first polymer and the second polymer are substantially uniformly distributed throughout the first polymeric film.

[0197] Aspect 47: The composite material of any one of aspects 1-46, wherein the third polymer and the fourth polymer are substantially uniformly distributed throughout the second polymeric film.

[0198] Aspect 48: The composite material of any one of aspects 1-47, wherein the first polymer and the second polymer are substantially uniformly distributed throughout the first polymeric film in a random manner.

[0199] Aspect 49: The composite material of any one of aspects 1-48, wherein the third polymer and the fourth polymer are substantially uniformly distributed throughout the second polymeric film in a random manner.

[0200] Aspect 50: The composite material of any one of aspects 1-49, wherein the first polymer is a polyester, a polyamide, or a polystyrene or a combination thereof.

[0201] Aspect 51 : The composite material of aspect 50, wherein the first polymer is a polyester, wherein the polyester is polyethylene terephthalate.

[0202] Aspect 52: The composite material of aspect 50, wherein the first polymer is a polyamide, wherein the polyamide is selected from the group consisting of polyamide 6, polyamide 11, polyamide 12, copolymers thereof, and blends thereof.

[0203] Aspect 53: The composite material of any one of aspects 1 to 52, wherein the second polymer is a polyolefin.

[0204] Aspect 54: The composite material of aspect 53, wherein the polyolefin is selected from the group consisting of polyethylene, polypropylene, polybutylene, copolymers thereof, and blends thereof.

[0205] Aspect 55: The composite material of aspect 53, wherein the second polymer is a polyolefin, wherein the polyolefin is polypropylene.

[0206] Aspect 56: The composite material of any one of aspects 1 to 55, wherein the first polymer is polyethylene terephthalate, and wherein the second polymer is polypropylene.

[0207] Aspect 57: The composite material of any one of aspects 1 to 56, wherein the third polymer is a polyester, a polyamide, or polystyrene, or a combination thereof.

[0208] Aspect 58: The composite material of aspect 57, wherein the third polymer is a polyester, wherein the polyester is polyethylene terephthalate.

[0209] Aspect 59: The composite material of aspect 57, wherein the third polymer is a polyamide, wherein the polyamide is selected from the group consisting of polyamide 6, polyamide 11, polyamide 12, and copolymers and blends thereof.

[0210] Aspect 60: The composite material of any one of aspects 1 to 59, wherein the fourth polymer is a polyolefin.

[0211] Aspect 61: The composite material of aspect 60, wherein the polyolefin is selected from the group consisting of polyethylene, polypropylene, polybutylene, and copolymers and blends thereof.

[0212] Aspect 62: The composite material of aspect 60, wherein the fourth polymer is a polyolefin, wherein the polyolefin is polypropylene.

[0213] Aspect 63: The composite material of any one of aspects 1 to 62, wherein the third polymer is polyethylene terephthalate, and wherein the fourth polymer is polypropylene.

[0214] Aspect 64: The composite material of any one of aspects 1 to 63, wherein the first nonwoven comprises a spunbond nonwoven material.

[0215] Aspect 65: The composite material of any one of aspects 1 to 64, wherein the second nonwoven comprises a spunbond nonwoven material.

[0216] Aspect 66: A carpet comprising a primary backing material, wherein the primary backing material is the composite material of any one of aspects 1 to 65.

[0217] Aspect 67: A carpet comprising a secondary backing material, wherein the secondary backing material is the composite material of any one of aspects 1 to 65.

[0218] Aspect 68: A greige comprising: a) a primary backing material having a face side and a back side, wherein the primary backing material is the composite material of any one of aspects 1 to 65; and b) a plurality of fibers attached to the primary backing material, at least a portion of the plurality of fibers extending from the face side of the primary backing material to form a pile face.

[0219] Aspect 69: The greige of aspect 68, further comprising: c) a pre-coat composition applied to the back side of the primary backing material; and d) a secondary backing material having a face side and a back side, wherein the face side of the secondary backing material is adjacent to the pre-coat composition.

[0220] Aspect 70: The greige of aspect 69, further comprising: e) a polymeric film applied to the back side of the secondary backing material.

[0221] Aspect 71 : The greige of any one of aspects 69 to 70, wherein the secondary backing material is the composite material of any one of aspects 1 to 46.

[0222] Aspect 72: A greige comprising: a) a primary backing material having a face side and a back side; b) a plurality of fibers attached to the primary backing material, at least a portion of the plurality of fibers extending from the face side of the primary backing material to form a pile face; c) a pre-coat composition applied to the back side of the primary backing material; and d) a secondary backing material having a face side and a back side, wherein the face side of the secondary backing material is adjacent to the pre-coat composition, and wherein the secondary backing material is the composite material of any one of aspects 1 to 65.

[0223] Aspect 73: The greige of aspect 72, further comprising: e) a polymeric film applied to the back side of the secondary backing material.

[0224] Aspect 74: A method of making a composite material, comprising the step of laminating: a) a continuous or discontinuous first polymeric film having a front side and a back side, wherein the first polymeric film comprises a first polymeric blend comprising a first polymer and a second polymer, wherein the first polymer is immiscible with the second polymer; b) a first nonwoven having a front side and a back side, wherein the front side of the first nonwoven contacts the back side of the first polymeric film; c) a continuous or discontinuous second polymeric film having a front side and a back side, wherein the second polymeric film comprises a second polymeric blend comprising a third polymer and a fourth polymer, wherein the third polymer is immiscible with the fourth polymer, wherein the front side of the second polymeric film contacts the back side of the first nonwoven; and d) a second nonwoven having a front side and a back side, wherein the front side of the second nonwoven contacts the back side of the second polymeric film, thereby making the composite material.

[0225] Aspect 75: The method of aspect 74, wherein the composite material is the composite material of any one of aspects 1 to 65.

[0226] Aspect 76: A greige good, comprising: a) a primary backing material having a front side and a back side, wherein the primary backing material comprises: i) a continuous or discontinuous first polymeric film having a front side and a back side, wherein the first polymeric film comprises a first polymeric blend comprising a first polymer and a second polymer, wherein the first polymer is immiscible with the second polymer; and ii) a continuous or discontinuous second polymeric film having a front side and a back side, wherein the second polymeric film comprises a second polymeric blend comprising a third polymer and a fourth polymer, wherein the third polymer is immiscible with the fourth polymer, wherein the front side of the second polymeric film contacts the back side of the first polymeric film; wherein the first polymeric film is an extruded film and the second polymeric film is an extruded film, wherein the first polymeric film and the second polymeric film are extruded in a direction transverse to the cross direction; and b) a plurality of fibers attached to the primary backing material, at least a portion of the plurality of fibers extending from the front side of the primary backing material to form a pile surface.

[0227] Aspect 77: The greige good of aspect 76, further comprising: c) a pre-coat composition applied to the back side of the primary backing material; and d) a secondary backing material having a front side and a back side, wherein the front side of the secondary backing material is adjacent to the pre-coat composition.

[0228] Aspect 78: The greige good of aspect 77, further comprising: e) a polymeric film coated to the back face of the secondary backing material.

[0229] Aspect 79: The greige good of any one of aspects 76-78, wherein the secondary backing material is the composite material of any one of aspects 1-65.

[0230] E. Examples

[0231] The following examples are put forth so as to provide those of ordinary skill in the art with a complete disclosure and description of how to make and evaluate the compounds, compositions, articles, devices, and / or methods claimed, and are intended to be purely exemplary and are not intended to limit the disclosure. Efforts have been made to ensure accuracy with respect to numbers (e.g., amounts, temperature, etc.); however, some errors and deviations can have occurred. Unless indicated otherwise, parts are parts by weight, temperature is in °C or at ambient temperature, and pressure is at or near atmospheric pressure.

[0232] 1. Example 1

[0233] The purpose of this example is to demonstrate that tufting can be performed using the disclosed composite material, and thus to demonstrate that the disclosed composite material can be used as a backing material, such as a primary backing material.

[0234] Figures 1A-1B The data in Table 1 demonstrates that the composite material disclosed herein can be used as a primary backing material in the carpet industry.

[0235] A continuous 160 pm thick polymeric film was made from a blend of polypropylene (PP) and polyethylene terephthalate (PET) from PP / PET fiber film. The following four (4) samples were made into cast films as follows: a) a film made from 95 wt% PP and 5 wt% PET; b) a film made from 75 wt% PP and 25 wt% PET; c) a film made from 50 wt% PP and 50 wt% PET; and d) a film made from 25 wt% PP and 75 wt% PET. A stretched film was also made from 75 wt% PP and 25 wt% PET with a stretch ratio of 12X (in an Instron set to 115 °C).

[0236] A two-layer composite material was made by laminating two films perpendicular to each other.

[0237] Tufting was performed with the produced composite material. The tufting machine used cut pile, with a needle count set to 10 needles per inch, and a needle gauge of 5 / 32.

[0238] During tufting, the woven cloth is used as a carrier for the test sample. A hole is cut in the woven cloth, which is covered by the composite test sample. The test sample is attached to the woven material at the edges using a backing tape.

[0239] The results of the tufting process can be seen in Table 1.

[0240] Table 1

[0241]

[0242]

[0243] Various different cut piles were successfully tufted into the cast film 3. The cast film 3 can be used as a primary backing material for the carpet industry. Figures 1A-1B A photo showing the successfully tufted cast film 3.

[0244] 2. Example 2

[0245] Stretch films produced in the machine direction (MDO) using high content PP and low content PET were used to make composites. Such films would split when hit by the tufting needle, but the nonwoven cloth prevents the slit from spreading uncontrolled and thus prevents the composite from being damaged during the tufting process. Therefore, tufting was successfully performed in such composites. Thus, composites using stretch films are suitable for use as backing materials, such as primary backing materials in the textile industry.

[0246] Films made from 95 wt% PP and 5 wt% PET during extrusion were stretched in the MDO at ratios of 5X, 6X and 7X and in the cross direction (TD) at 1X (unstretched). The stretch temperature of the films was set to 160°C.

[0247] The data related to the stretch films are shown in Table 2.

[0248] Table 2

[0249]

[0250] Four-layer composites were made by using two middle layers of the above-mentioned 5X and 6X stretch films and two outer layers of a spunbond nonwoven material (40 gsm spunbond) during lamination.

[0251] Tufting was performed with the produced composites. The tufting machine used loops and was set to 9 needles per inch and a needle gauge of 5 / 32.

[0252] The results of the tufting process can be seen in Table 3.

[0253] Table 3

[0254]

[0255] The composite of the polymer blend using 95 wt% PP and 5 wt% PET provided robust performance in the tufting process for the polymer film stretched at 5X and 6X, which indicates that the composite is suitable for use as a backing material, such as a primary backing material in the textile industry. Figures 2A-2B A photograph showing the composite tufted successfully using the polymer film stretched at 6X is shown. Thus, this demonstrates the feasibility of the composite with the stretched film for use as a primary backing material in the carpet industry.

[0256] The patentable scope of the present application is defined by the claims, and can include other examples as can occur to those skilled in the art. If these other examples are not different from the literal language of the claims, or if they include equivalent structure for the same function, then they are intended to be within the scope of the claims.

[0257] While the preferred form of the application has been disclosed, it will be apparent to those skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope of the application. Accordingly, the scope of the application is to be limited only by the appended claims.

Claims

1. A composite comprising: a. a continuous or discontinuous first polymeric film having a face side and a back side, wherein the first polymeric film comprises a first polymeric blend comprising a first polymer and a second polymer, wherein the first polymer is immiscible with the second polymer, wherein the first polymeric film is stretched; b. a first nonwoven having a face side and a back side, wherein the face side of the first nonwoven contacts the back side of the first polymeric film; c. a continuous or discontinuous second polymeric film having a face side and a back side, wherein the second polymeric film comprises a second polymeric blend comprising a third polymer and a fourth polymer, wherein the third polymer is immiscible with the fourth polymer, wherein the face side of the second polymeric film contacts the back side of the first nonwoven, wherein the second polymeric film is stretched; and d. a second nonwoven having a face side and a back side, wherein the face side of the second nonwoven contacts the back side of the second polymeric film, wherein the composite comprises a machine direction and a cross direction; and i) the stretch direction of the first polymeric film is disposed in the machine direction of the composite, and the stretch direction of the second polymeric film is disposed in the cross direction of the composite; or ii) the stretch direction of the second polymeric film is disposed in the machine direction of the composite, and the stretch direction of the first polymeric film is disposed in the cross direction of the composite.

2. A composite comprising: a. a continuous or discontinuous first polymeric film having a face side and a back side, wherein the first polymeric film comprises a first polymeric blend comprising a first polymer and a second polymer, wherein the first polymer is immiscible with the second polymer, the first polymeric film is stretched along a single stretch direction; b. a first nonwoven having a face side and a back side; c. a continuous or discontinuous second polymeric film having a face side and a back side, wherein the second polymeric film comprises a second polymeric blend comprising a third polymer and a fourth polymer, wherein the third polymer is immiscible with the fourth polymer, the second polymeric film is stretched along a single stretch direction; and d. a second nonwoven having a face side and a back side, wherein the composite comprises a machine direction and a cross direction; and i) the single stretch direction of the first polymeric film is disposed in the machine direction of the composite, and the single stretch direction of the second polymeric film is disposed in the cross direction of the composite; or ii) the single stretch direction of the first polymeric film is disposed in the cross direction of the composite, and the single stretch direction of the second polymeric film is disposed in the machine direction of the composite, wherein the composite is suitable for use as a backing for a carpet, wherein the composite is configured to be tufted in the composite, wherein The front side of the second polymer film contacts the back side of the first polymer film, the front side of the first polymer film contacts the back side of the first nonwoven fabric, and the front side of the first nonwoven fabric contacts the back side of the second nonwoven fabric. or The front side of the second polymer film contacts the back side of the first polymer film, the front side of the first nonwoven fabric contacts the back side of the second polymer film, and the front side of the second nonwoven fabric contacts the back side of the first nonwoven fabric. or The front side of the first nonwoven fabric contacts the back side of the first polymer film, the front side of the second nonwoven fabric contacts the back side of the first nonwoven fabric, and the front side of the second polymer film contacts the back side of the second nonwoven fabric. or The front side of the first polymer film contacts the back side of the first nonwoven fabric, the front side of the second nonwoven fabric contacts the back side of the first polymer film, and the front side of the second polymer film contacts the back side of the second nonwoven fabric.

3. A composite material comprising: a. A first polymer film having a front and a back side, either continuous or discontinuous, wherein the first polymer film comprises a first polymer blend, the first polymer blend comprising a first polymer and a second polymer, wherein the first polymer and the second polymer are immiscible, and wherein the first polymer film is stretched. b. A first nonwoven fabric having a front and a back; and c. A continuous or discontinuous second polymer film having a front and a back side, wherein the second polymer film comprises a second polymer blend, the second polymer blend comprising a third polymer and a fourth polymer, wherein the third polymer and the fourth polymer are immiscible, wherein the second polymer film is stretched. The first nonwoven fabric is disposed between the back side of the first polymer film and the front side of the second polymer film; The composite material comprises longitudinal and transverse directions; and i) The stretching direction of the first polymer film is disposed in the longitudinal direction of the composite material, and the stretching direction of the second polymer film is disposed in the transverse direction of the composite material; or ii) The stretching direction of the first polymer film is disposed in the transverse direction of the composite material, and the stretching direction of the second polymer film is disposed in the longitudinal direction of the composite material. The composite material described therein is suitable for use as a carpet backing. The composite material is configured to be tufted within it. The front side of the first nonwoven fabric contacts the back side of the first polymer film, and the front side of the second polymer film contacts the back side of the first nonwoven fabric.

4. The composite material according to any one of claims 1 to 3, wherein the composite material comprises a continuous first polymer film.

5. The composite material according to any one of claims 1 to 3, wherein the composite material comprises a continuous second polymer film.

6. The composite material according to any one of claims 1 to 3, wherein the composite material comprises a continuous first polymer film and a continuous second polymer film.

7. The composite material according to any one of claims 1 to 3, wherein the composite material comprises a discontinuous first polymer film.

8. The composite material according to any one of claims 1 to 3, wherein the composite material comprises a discontinuous second polymer film.

9. The composite material according to any one of claims 1 to 3, wherein the composite material comprises a discontinuous first polymer film and a discontinuous second polymer film.

10. The composite material according to any one of claims 1 to 3, wherein the composite material comprises a continuous first polymer film and a discontinuous second polymer film.

11. The composite material according to any one of claims 1 to 3, wherein the composite material comprises a discontinuous first polymer film and a continuous second polymer film.

12. The composite material according to any one of claims 1 to 3, wherein the composite material is a laminated composite material.

13. The composite material according to any one of claims 1 to 3, wherein the first polymer film is an extruded film.

14. The composite material according to any one of claims 1 to 3, wherein the second polymer film is an extruded film.

15. The composite material according to any one of claims 1 to 3, wherein the first polymer film and the second polymer film are extruded in the same direction.

16. The composite material according to any one of claims 1 to 3, wherein the first polymer film and the second polymer film are extruded in a mutually transverse direction.

17. The composite material according to any one of claims 1 to 2, wherein the composite material has a front side and a back side, wherein the front side of the composite material is the front side of the first polymer film, and wherein the back side of the composite material is the back side of the second nonwoven fabric.

18. The composite material according to any one of claims 1 to 3, wherein the first polymer blend and the second polymer blend are substantially the same.

19. The composite material according to any one of claims 1 to 3, wherein the first polymer blend comprises 1% to 99% by weight of the first polymer and 99% to 1% by weight of the second polymer.

20. The composite material according to any one of claims 1 to 3, wherein the first polymer blend comprises 5% to 50% by weight of the first polymer and 95% to 50% by weight of the second polymer.

21. The composite material according to any one of claims 1 to 3, wherein the first polymer blend comprises 20% to 30% by weight of the first polymer and 80% to 70% by weight of the second polymer.

22. The composite material according to any one of claims 1 to 3, wherein the second polymer blend comprises 1% to 99% by weight of the third polymer and 99% to 1% by weight of the fourth polymer.

23. The composite material according to any one of claims 1 to 3, wherein the second polymer blend comprises 5% to 50% by weight of the third polymer and 95% to 50% by weight of the fourth polymer.

24. The composite material according to any one of claims 1 to 3, wherein the second polymer blend comprises 20% to 30% by weight of the third polymer and 80% to 70% by weight of the fourth polymer.

25. The composite material according to any one of claims 1 to 3, wherein the first polymer film comprises two or more alternating layers of the first polymer and the second polymer.

26. The composite material according to any one of claims 1 to 3, wherein the second polymer film comprises two or more alternating layers of the third polymer and the fourth polymer.

27. The composite material according to any one of claims 1 to 3, wherein the first polymer film is contained in the filaments of the first polymer within the continuous phase of the second polymer.

28. The composite material according to any one of claims 1 to 3, wherein the second polymer film is contained in the filaments of the third polymer within the continuous phase of the fourth polymer.

29. The composite material according to any one of claims 1 to 3, wherein the first polymer and the second polymer are substantially uniformly distributed throughout the first polymer film.

30. The composite material according to any one of claims 1 to 3, wherein the third polymer and the fourth polymer are substantially uniformly distributed throughout the second polymer film.

31. The composite material according to any one of claims 1 to 3, wherein the first polymer and the second polymer are distributed substantially uniformly throughout the first polymer film in a random manner.

32. The composite material according to any one of claims 1 to 3, wherein the third polymer and the fourth polymer are distributed substantially uniformly throughout the second polymer film in a random manner.

33. The composite material according to any one of claims 1 to 3, wherein the first polymer is polyester, polyamide, or polystyrene or a combination thereof.

34. The composite material according to claim 33, wherein the first polymer is a polyester, and wherein the polyester is polyethylene terephthalate.

35. The composite material according to claim 33, wherein the first polymer is a polyamide, wherein the polyamide is selected from the group consisting of polyamide 6, polyamide 11, polyamide 12, copolymers thereof, and blends thereof.

36. The composite material according to any one of claims 1 to 3, wherein the second polymer is a polyolefin.

37. The composite material of claim 36, wherein the polyolefin is selected from the group consisting of polyethylene, polypropylene, polybutene, copolymers thereof, and blends thereof.

38. The composite material according to claim 36, wherein the second polymer is a polyolefin, and wherein the polyolefin is polypropylene.

39. The composite material according to any one of claims 1 to 3, wherein the first polymer is polyethylene terephthalate, and wherein the second polymer is polypropylene.

40. The composite material according to any one of claims 1 to 3, wherein the third polymer is polyester, polyamide, or polystyrene or a combination thereof.

41. The composite material according to claim 40, wherein the third polymer is a polyester, wherein the polyester is polyethylene terephthalate.

42. The composite material of claim 40, wherein the third polymer is a polyamide, wherein the polyamide is selected from the group consisting of polyamide 6, polyamide 11, polyamide 12, copolymers and blends thereof.

43. The composite material according to any one of claims 1 to 3, wherein the fourth polymer is a polyolefin.

44. The composite material of claim 43, wherein the polyolefin is selected from the group consisting of polyethylene, polypropylene, polybutene, copolymers and blends thereof.

45. The composite material according to claim 43, wherein the fourth polymer is a polyolefin, and wherein the polyolefin is polypropylene.

46. ​​The composite material according to any one of claims 1 to 3, wherein the third polymer is polyethylene terephthalate, and wherein the fourth polymer is polypropylene.

47. The composite material according to any one of claims 1 to 3, wherein the first nonwoven fabric comprises a spunbond nonwoven material.

48. The composite material according to any one of claims 1 to 2, wherein the second nonwoven fabric comprises a spunbond nonwoven material.

49. A carpet comprising a backing material, wherein the backing material is a composite material according to any one of claims 1 to 48.

50. A carpet comprising a backing material, wherein the backing material is a composite material according to any one of claims 1 to 48.

51. A grey fabric comprising: a. A main backing material having a front and a back, wherein the main backing material is a composite material according to any one of claims 1 to 48; and b. A plurality of fibers attached to the main backing material, at least a portion of which extends from the front side of the main backing material to form a napped surface.

52. The grey fabric according to claim 51, further comprising: c. A pre-coating composition applied to the back side of the main backing material; and d. A sub-backing material having a front and a back, wherein the front of the sub-backing material is adjacent to the pre-coated composition.

53. The grey fabric according to claim 52, further comprising: e. A polymer film applied to the back side of the sub-backing material.

54. The fabric according to claim 52, wherein the secondary backing material is a composite material according to any one of claims 1 to 48.

55. A grey fabric comprising: a. A main backing material with a front and a back; b. A plurality of fibers attached to the main backing material, at least a portion of the plurality of fibers extending from the front side of the main backing material to form a napped surface; c. A pre-coating composition applied to the back side of the main backing material; and d. A sub-backing material having a front and a back, wherein the front of the sub-backing material is adjacent to the pre-coated composition, and wherein the sub-backing material is a composite material according to any one of claims 1 to 48.

56. The grey fabric according to claim 55, further comprising: e. A polymer film applied to the back side of the sub-backing material.

57. A method for manufacturing a composite material, comprising the step of laminating the following substances: a. A first polymer film having a front and a back side, either continuous or discontinuous, wherein the first polymer film comprises a first polymer blend, the first polymer blend comprising a first polymer and a second polymer, wherein the first polymer and the second polymer are immiscible, and wherein the first polymer film is stretched. b. A first nonwoven fabric having a front side and a back side, wherein the front side of the first nonwoven fabric contacts the back side of the first polymer film; c. A continuous or discontinuous second polymer film having a front and a back side, wherein the second polymer film comprises a second polymer blend, the second polymer blend comprising a third polymer and a fourth polymer, wherein the third polymer and the fourth polymer are immiscible, wherein the front side of the second polymer film contacts the back side of the first nonwoven fabric, wherein the second polymer film is stretched. and d. A second nonwoven fabric having a front side and a back side, wherein the front side of the second nonwoven fabric contacts the back side of the second polymer film. Thus, the composite material is produced. The composite material comprises longitudinal and transverse directions; and i) The stretching direction of the first polymer film is disposed in the longitudinal direction of the composite material, and the stretching direction of the second polymer film is disposed in the transverse direction of the composite material; or ii) The stretching direction of the second polymer film is disposed in the longitudinal direction of the composite material, and the stretching direction of the first polymer film is disposed in the transverse direction of the composite material.

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