Carpet primary base fabric

Abstract

A carpet primary backing comprising a construction of at least three layers, wherein a first layer and a third layer comprise a fibrous nonwoven layer, a second layer comprises a fibrous reinforcing layer, the second layer being located between the first and third layers, and wherein the fibrous nonwoven layer of the first layer has a maximum flow rate of 8000 L / m2 measured in accordance with ISO 9237:1995. 2 The third layer of fibrous nonwoven fabric has an air permeability of at least 1000 L / m² measured in accordance with ISO 9237:1995. 2 a material having an air permeability of s, wherein the first layer of nonwoven fibrous layer has a lower air permeability than the third layer of nonwoven fibrous layer.

Description

[Technical field]

[0001] TECHNICAL FIELD This application relates to a carpet primary backing, a tufted carpet including a carpet primary backing, and a method for making such tufted carpet including a carpet primary backing.

[0002] In traditional carpet tile manufacturing, there are many layers of various materials behind the visible pile yarns. The structure behind the pile yarns includes a carpet primary backing onto which the pile yarns are tufted, which includes a precoat to hold the pile yarns in place. Under the tufted and precoated primary backing, a conventional carpet tile includes a polymer layer, a reinforcing layer, an additional polymer layer, and an optional carpet secondary backing.

[0003] This reinforcing layer can be, for example, a fiberglass nonwoven or scrim, and provides reinforcement in the plane (x and y dimensions) of the carpet tile. A layer of polymer coating is required between the primary carpet backing and the reinforcing layer, and between the secondary carpet backing and the reinforcing layer, to transfer the generated forces applied in the x and / or y directions of the carpet tile to the reinforcing layer.

[0004] These layers of polymer coating are expensive and although carpet tile manufacturers strive to minimize the mass of these two layers of polymer coating, a minimum amount of polymer is required as this is critical for adequate bonding between the reinforcing layer and the primary carpet backing and / or the secondary carpet backing.

[0005] In some carpet tiles, the reinforcing layer has been moved from between two layers of polymer to just above the secondary carpet backing, allowing two layers of expensive polymer coating to be reduced to only one layer, reducing the total mass of polymer in the carpet tile.

[0006] WO 2011 / 069996 discloses a primary carpet backing comprising a first layer and a second layer of fibers, both of which are nonwoven layers of randomly laid fibers, and the fibers of the first layer and the second layer comprise at least two different polymers.

[0007] WO 2016 / 00869 discloses a polyvinyl chloride-free decorative surface comprising a reinforcing layer that is impregnated with a polyvinyl chloride-free paste, whereby the polyvinyl chloride-free paste is found on both sides of the surface coating.

[0008] GB 1,409,068 discloses a method for applying a secondary backing to a tufted primary backing, in which reinforcement of the secondary backing is provided by warp yarns which are integrated into the knitted structure and which are introduced during and as part of the knitting process.

[0009] However, while it is possible to reduce the number of layers of polymeric coating by moving the reinforcing layer above the secondary carpet backing, the drawback is that additional adhesive must be used to adhere the reinforcing layer to the secondary carpet backing. Without being bound by theory, it is believed that moving the reinforcing layer above the secondary carpet backing has negative consequences on flatness stability (perpendicular to the plane of the carpet tile, the z dimension), such as edge curling and curling of the carpet tile.

[0010] Additionally, if the layer of polymeric coating has a high affinity for the primary carpet backing, the polymeric coating may become visible on the surface of the carpet, known as latex bleeding.

[0011] It is an object of the present application to provide a material for a carpet primary backing, a tufted carpet comprising a carpet primary backing, and a method for manufacturing such a tufted carpet comprising a carpet primary backing, which avoids or at least reduces the aforementioned disadvantages.

[0012] The object is to provide a material for a carpet primary backing comprising a structure of at least three layers, in which a first layer and a third layer comprise a fibrous nonwoven layer, a second layer comprises a fibrous reinforcing layer, the second layer being located between the first and third layers, the fibrous nonwoven layer of the first layer having a maximum viscosity of 8000 l / m2 measured according to ISO 9237:1995. 2 s and the textile nonwoven layer of the third layer has an air permeability of at least 3500 l / m2 measured in accordance with ISO 9237:1995 2 The objective of the present invention is to provide a carpet primary backing material having an air permeability of 100-150 mm / s, the nonwoven layer of fibers of the first layer having a lower air permeability than the nonwoven layer of fibers of the third layer. Throughout this application, the terms "carpet primary backing material" and "carpet primary backing" are used synonymously.

[0013] For clarity, the measurement of air permeability according to ISO 9237:1995 is performed at a pressure of 200 Pa and a 2 In addition, the characteristic that the nonwoven layer of fiber of the first layer has a lower air permeability than the nonwoven layer of fiber of the third layer is also referred to as "air permeability asymmetry of the carpet primary backing" for ease of reading and conciseness.

[0014] The fact that the primary carpet backing includes a reinforcing layer of fiber improves the flatness stability perpendicular to the plane of the carpet tile (z dimension), such as edge curl and curling of the carpet tile. The fact that the primary carpet backing includes a third layer including a nonwoven layer of fiber with minimal air permeability improves the penetration of the precoat applied to the tufted primary carpet backing, while the first layer including a nonwoven layer of fiber with low air permeability prevents bleeding of the latex of the precoat onto the carpet tile surface.

[0015] For clarity, the following provides an explanation of some terms and phrases used in this application.

[0016] The term "composite material" should be understood as a material made from two or more constituent materials that have significantly different physical or chemical properties, which, when combined, produce a material with characteristics different from those of the individual components.

[0017] The phrase "substantially parallel" means that the fibers of the unidirectional layers are spaced apart from one another so that the fibers do not contact adjacent fibers of the unidirectional fibrous layers.

[0018] The terms "spunbond" and "spunlaid" refer to the production of a nonwoven layer of fibers in which fibers are extruded through a spinneret and subsequently laid on a conveyor belt as a web of filaments, and the web is then bonded to form a nonwoven layer of fibers, or to the production of a nonwoven layer of fibers by a two-step process in which filaments are spun, optionally drawn using, for example, a drawing godet or a jet of compressed air, and wound onto bobbins, for example in the form of a multifilament yarn, and subsequently the multifilament yarn is unwound, the filaments are laid on a conveyor belt as a web of filaments, and the web is then bonded to form a nonwoven layer of fibers.

[0019] The term "carpet face" should be understood as the side of the carpet that is visible when the carpet is laid on the ground. When the carpet is laid on the ground, the side that is not visible is the side that has the tufting backstitching.

[0020] Within the scope of this application, the term "fiber" is understood to refer to both staple fibers and filaments. Staple fibers are fibers having a defined, relatively short length, ranging from 2 to 200 mm. Filaments are fibers having a length greater than 200 mm. In one embodiment, filaments are fibers having a length greater than 500 mm. In one embodiment, filaments are fibers having a length greater than 1000 mm. Filaments may be virtually infinite, for example when formed by continuous extrusion and spinning of the filaments through spinning holes in a spinneret.

[0021] Within the scope of this application, the "machine direction" is understood to be the direction of manufacture as it is the largest dimension of the carpet primary backing, which may also be synonymously referred to as the x-direction. Additionally, the "cross-machine direction" is the second largest dimension of the carpet primary backing that is in the same plane as the machine direction and perpendicular to the machine direction, which may also be synonymously referred to as the y-direction. The dimension that is out of plane and perpendicular to the machine and cross-machine directions is the third largest dimension of the carpet primary backing, which is the z-direction.

[0022] In one embodiment, the fibers of the nonwoven layer of fibers of the first layer and / or the fibers of the nonwoven layer of fibers of the third layer are filaments.

[0023] The primary carpet backing includes a fibrous reinforcing layer, which may be constructed from any suitable material capable of providing reinforcement. There are several classifications of materials available, such as high resilience materials, low shrinkage materials, and materials that are resistant to compression.

[0024] Every class of material has its own properties that are beneficial to the stability of the primary carpet backing. High resilience materials provide the primary carpet backing with the beneficial property of increased stability against elongation. Low shrinkage materials provide the primary carpet backing with the beneficial property of increased stability against shrinkage, for example, when temperatures above ambient temperature affect the primary carpet backing. Additionally, materials that are resistant to compression increase the primary carpet backing's stability against compression, e.g., stiffness, when, for example, shrinkage of tufted yarns exerts a compressive force on the primary carpet backing.

[0025] In one embodiment, the fibers of the fibrous reinforcing layer have a tensile modulus of at least 25 GPa. In one embodiment, the fibers of the fibrous reinforcing layer have a tensile modulus of at least 40 GPa. In one embodiment, the fibers of the fibrous reinforcing layer have a tensile modulus of at least 50 GPa. In one embodiment, the fibers of the fibrous reinforcing layer have a tensile modulus of at least 75 GPa.

[0026] In one embodiment, the fibers of the reinforcing layer have a linear density of up to 50 tex. In one embodiment, the fibers of the reinforcing layer have a linear density of up to 40 tex. In one embodiment, the fibers of the reinforcing layer have a linear density of up to 30 tex. In one embodiment, the fibers of the reinforcing layer have a linear density of up to 28 tex. In one embodiment, the fibers of the reinforcing layer have a linear density of up to 20 tex. In one embodiment, the fibers of the reinforcing layer have a linear density of up to 15 tex.

[0027] In one embodiment of the present application, the asymmetry in the air permeability of the primary carpet backing is introduced by the weight ratio of the fibrous nonwoven layer of the first layer to the fibrous nonwoven layer of the third layer, with the fibrous nonwoven layer of the first layer desirably having a greater weight than the fibrous nonwoven layer of the third layer.

[0028] The weight ratio of the first layer to the third layer is at least 60:40. In one embodiment, the weight ratio of the first layer to the third layer is at least 70:30. The weight ratio of the first layer to the third layer is at least 80:20. The weight ratio of the first layer to the third layer is at least 90:10.

[0029] In one embodiment, the first layer comprising a nonwoven layer of fibers has a weight of at least 60 g / m 2 In one embodiment, the weight of the first layer comprising a nonwoven layer of fibers is at least 70 g / m 2 In one embodiment, the weight of the first layer comprising a nonwoven layer of fibers is at least 80 g / m 2 In one embodiment, the weight of the first layer comprising a nonwoven layer of fibers is at least 90 g / m 2 In all cases weight is determined according to ISO 9073-1.

[0030] In one embodiment, the third layer, which comprises a nonwoven layer of fibers, has a weight of up to 40 g / m 2 In one embodiment, the third layer comprising a nonwoven layer of fibers has a weight of up to 30 g / m 2 In one embodiment, the third layer, which comprises a nonwoven layer of fibers, has a weight of up to 20 g / m 2In one embodiment, the third layer comprising a nonwoven layer of fibers has a weight of up to 10 g / m 2 Weight is determined in all cases according to ISO 9073-1.

[0031] A higher weight of the first layer of fibrous nonwoven layer may result in increased fiber surface coverage in the first layer of fibrous nonwoven layer and decreased fiber surface coverage in the third layer of fibrous nonwoven layer.

[0032] In one embodiment, the first layer comprising a fibrous nonwoven layer has a surface coverage of 1% to 40%. In one embodiment, the first layer comprising a fibrous nonwoven layer has a surface coverage of 2% to 30%. In one embodiment, the first layer comprising a fibrous nonwoven layer has a surface coverage of 3% to 25%. In one embodiment, the first layer comprising a fibrous nonwoven layer has a surface coverage of 5% to 20%. The surface coverage A is calculated in the following manner: A = χ*d; where χ is the number of filaments per filament layer and d is the diameter of the filament. The number of filaments per layer, χ, is calculated in the following way: χ = N / L; where N is the number of layers of filaments and L is the total length of the filaments per area unit. The quantities N and L are calculated in the following manner: N = T / d; where d is the thickness of the filament when a monofilament is used and d is the thickness of the filament core when a bicomponent filament is used. L=M*t; where T is the thickness of the first layer of fibers, M is the basis weight of the first layer of fibers, and t is the linear density of the filaments. 2 The pressure is determined in accordance with DIN ISO 9073-2 using a presser foot of 0.05 kPa and a pressure of 0.05 kPa.

[0033] Without being bound by theory, increasing the surface coverage of the fibers in the nonwoven layer of fibers of the first layer can result in lower air permeability, which can result in reduced fluid permeability, for example, of a polymeric coating and / or pre-coating.

[0034] Alternatively, a reduction in the surface coverage of the fibers in the nonwoven layer of fibers of the third layer can result in higher air permeability, which in turn can increase the permeability of fluids, such as, for example, a polymeric coating and / or pre-coating.

[0035] In one embodiment, the third layer comprising a fibrous nonwoven layer has a surface coverage of 1% to 40%. In one embodiment, the third layer comprising a fibrous nonwoven layer has a surface coverage of 2% to 30%. In one embodiment, the third layer comprising a fibrous nonwoven layer has a surface coverage of 3% to 25%. In one embodiment, the third layer comprising a fibrous nonwoven layer has a surface coverage of 5% to 20%.

[0036] Asymmetry in the air permeability of the carpet primary backing may also be introduced by different average diameters of the fibers contained in the nonwoven layer of fibers of the first layer and the nonwoven layer of fibers of the third layer.

[0037] In one embodiment, the fibers in the first layer have an average diameter that is smaller than the average diameter of the fibers in the third layer.

[0038] In one embodiment, the average diameter of the fibers of the nonwoven layer of fibers of the first layer is at most 50 μm. In one embodiment, the average diameter of the fibers of the nonwoven layer of fibers of the first layer is at most 30 μm. In one embodiment, the average diameter of the fibers of the nonwoven layer of fibers of the first layer is at most 25 μm. In one embodiment, the average diameter of the fibers of the nonwoven layer of fibers of the first layer is at most 20 μm.

[0039] In one embodiment, the average diameter of the fibers of the nonwoven layer of fibers of the third layer is at least 30 μm. In one embodiment, the average diameter of the fibers of the nonwoven layer of fibers of the third layer is at least 35 μm. In one embodiment, the average diameter of the fibers of the nonwoven layer of fibers of the third layer is at least 40 μm. In one embodiment, the average diameter of the fibers of the nonwoven layer of fibers of the third layer is at least 50 μm. In one embodiment, the average diameter of the fibers of the nonwoven layer of fibers of the third layer is at least 60 μm.

[0040] Without being bound by theory, it is believed that the smaller average diameter of the fibers in the first layer of fibrous nonwoven fabric layer and the larger average diameter of the fibers in the third layer of fibrous nonwoven fabric layer can result in a difference in fiber surface coverage between the first layer of fibrous nonwoven fabric layer and the third layer of fibrous nonwoven fabric layer.

[0041] For example, in a nonwoven layer of fibers in the first layer, if the average diameter of the fibers is reduced while keeping the weight of the layer constant, the fiber length value per square meter of the nonwoven layer of fibers in the first layer (m / m 2 ), i.e., fiber length per surface area, is increased, which can result in increased surface coverage of the fibers in the nonwoven layer of fibers of the first layer.

[0042] For example, in a nonwoven layer of a third layer of fiber, if the average diameter of the fibers is increased while keeping the weight of the layer constant, the fiber length value per square meter of the nonwoven layer of the third layer of fiber (m / m 2 ) is reduced, which can result in a reduced surface coverage of the fibers in the nonwoven layer of fibers of the third layer.

[0043] Thus, without being bound by theory, it is believed that, for example, in a nonwoven layer of fibers in the first layer, a higher weight of the fiber layer combined with a smaller average diameter of the fibers in the layer can synergistically assist in the effects of lower air permeability and lower permeability to fluids, such as, for example, a polymer coating and / or pre-coating.

[0044] Alternatively, a smaller weight of a layer of fibers, such as a nonwoven layer of fibers in a third layer, combined with a larger average diameter of the fibers in the layer, can synergistically support the effects of greater air permeability and greater permeability to fluids, such as a polymer coating and / or pre-coating.

[0045] The first layer of fibrous nonwoven layer and / or the third layer of fibrous nonwoven layer can include monocomponent fibers, two types of monocomponent fibers, and / or bicomponent fibers.

[0046] The first layer fibrous nonwoven layer and / or the third layer fibrous nonwoven layer can be manufactured by any suitable process, such as a spunlaid process, an airlaid process, a wetlaid process, a meltblowing process, or a carding process.

[0047] In one embodiment, the first layer of nonwoven fiber layer and / or the third layer of nonwoven fiber layer are manufactured by a spunlaid process, and the fibers are manufactured from a thermoplastic polymer-based material. In the spunlaid process, the fibers of the first layer of nonwoven fiber layer and / or the fibers of the third layer of nonwoven fiber layer can be bonded by any suitable process, including hydroentanglement, needling, chemical bonding, calendaring, ultrasonic bonding, and other thermal bonding methods, such as hot air bonding.

[0048] In one embodiment, the nonwoven layer of fibers of the first layer and / or the nonwoven layer of fibers of the third layer comprise two monocomponent fibers comprising two chemically distinct thermoplastic polymer-based materials, the two monocomponent fibers differing in melting temperature by at least 10° C. In one embodiment, the difference in melting temperature between the two thermoplastic polymer-based materials is 20° C. In one embodiment, the difference in melting temperature between the two thermoplastic polymer-based materials is 30° C. In one embodiment, the difference in melting temperature between the two thermoplastic polymer-based materials is 50° C.

[0049] In one embodiment, the fibers of the nonwoven layer of the first layer of fibers and / or the fibers of the nonwoven layer of the third layer of fibers are bicomponent fibers of concentric or eccentric core / sheath model, side-by-side model, segmented pie model, or islands-in-the-sea model.

[0050] In one embodiment, the fibers of the nonwoven layer of the first layer of fibers and / or the fibers of the nonwoven layer of the third layer of fibers are bicomponent fibers in a concentric core / sheath model, the fibers being made of the same class of thermoplastic polymer-based materials or chemically different thermoplastic polymer-based materials.

[0051] Within the scope of this application, thermoplastic materials of the same class mean that the same monomer units of the polymer can be used, but the thermoplastic polymer-based materials may differ by different polymer chain lengths, different densities of the thermoplastic polymer-based materials, or different orientations of the monomer units, which may be isotactic, syndiotactic, or atactic.

[0052] The core of the bicomponent fiber may comprise a thermoplastic polymer-based material having a higher melting temperature than the thermoplastic polymer-based material of the sheath. The melting temperatures of the thermoplastic polymer-based material of the core and the thermoplastic polymer-based material of the sheath may differ by at least 10°C. The melting temperatures of the thermoplastic polymer-based material of the core and the thermoplastic polymer-based material of the sheath may differ by at least 20°C. The melting temperatures of the thermoplastic polymer-based material of the core and the thermoplastic polymer-based material of the sheath may differ by at least 30°C. The melting temperatures of the thermoplastic polymer-based material of the core and the thermoplastic polymer-based material of the sheath may differ by at least 50°C.

[0053] The thermoplastic polymer-based material of the fibers of the nonwoven layer of fibers of the first layer of fibers and / or the fibers of the nonwoven layer of fibers of the third layer of fibers may be selected from the group including polyolefins such as polyethylene (PE) and polypropylene (PP); polyesters such as polyethylene terephthalate (PET), polytrimethylene terephthalate (PTT), polybutylene terephthalate (PBT), polyethylene naphthalate (PEN), polyethylene-1,2-furan dicarboxylate (PEF), and polylactic acid (PLA); polyamides such as polyamide 6,6 (PA6,6) and polyamide 6 (PA6); and copolymers and / or blends thereof.

[0054] In one embodiment, the fibers of the nonwoven layer of the first layer of fibers and / or the fibers of the nonwoven layer of the third layer of fibers comprise at least 50% by weight of a thermoplastic material. In one embodiment, the fibers of the nonwoven layer of the first layer of fibers and / or the fibers of the nonwoven layer of the third layer of fibers comprise at least 75% by weight of a thermoplastic material. In one embodiment, the fibers of the nonwoven layer of the first layer of fibers and / or the fibers of the nonwoven layer of the third layer of fibers comprise at least 85% by weight of a thermoplastic material. In one embodiment, the fibers of the nonwoven layer of the first layer of fibers and / or the fibers of the nonwoven layer of the third layer of fibers comprise at least 95% by weight of a thermoplastic material. In one embodiment, the fibers of the nonwoven layer of the first layer of fibers and / or the fibers of the nonwoven layer of the third layer of fibers comprise at least 97% by weight of a thermoplastic material.

[0055] In this regard, the thermoplastic polymer-based materials may include additives such as flame retardants, colorants, fillers, fungicides, and / or antimicrobial agents.

[0056] In one embodiment, the reinforcing layer included in the primary carpet backing may be a nonwoven, woven, laid scrim, woven scrim, unidirectional fiber layer, or knitted fabric.

[0057] In one embodiment, the reinforcing layer of the carpet primary backing is a laid scrim, a woven scrim, or a unidirectional fibrous layer, the fibers of the unidirectional fibrous layer being aligned substantially parallel to each other in the machine direction.

[0058] In one embodiment, the fibers (e.g., filaments) of a unidirectional fiber layer having a large length in terms of width and height are spaced apart from each other at a constant distance throughout the length of the unidirectional fiber layer. Within the scope of this application, a constant distance may mean that the shortest distance between two threads does not differ by more than 2 millimeters. Within the scope of this application, a constant distance may mean that the shortest distance between two threads does not differ by more than 1 millimeter. Within the scope of this application, a constant distance may mean that the shortest distance between two threads does not differ by more than 0.5 millimeters.

[0059] As is well known to those skilled in the art, a scrim, whether laid or woven, is an open lattice structure composed of at least two sets of parallel yarns, where a first group of parallel yarns is oriented at an angle, usually a 90° angle, to a second group of parallel yarns. The first group of parallel yarns can be bonded to the second group of parallel yarns by chemical bonding to form a laid scrim, or the first group of parallel yarns can be interwoven with the second group of parallel yarns to form a woven scrim. In one embodiment, the openings in the scrim have at least one dimension that is at least 1 mm in the plane of the scrim. In one embodiment, the openings in the scrim have at least one dimension that is at least 2 mm in the plane of the scrim. In one embodiment, the openings in the scrim have at least one dimension that is at least 5 mm in the plane of the scrim.

[0060] In one embodiment, the fibrous reinforcing layer included in the primary carpet backing comprises high modulus fibers comprised of materials selected from the group including glass, carbon, basalt, high modulus, low shrinkage (HMLS) polyester, inorganic materials, aramids such as para-aramid (PPTA) and meta-aramid (MPTA), and ultra-high molecular weight polyethylene (UHMWPE).

[0061] In one embodiment, the nonwoven layer of fibers of the first layer of the carpet primary backing has a fiber density of up to 7000 l / m 2 In one embodiment, the fibrous nonwoven layer of the first layer of the carpet primary backing can have an air permeability of up to 6000 l / m 2 In one embodiment, the fibrous nonwoven layer of the first layer of the carpet primary backing can have an air permeability of up to 5000 l / m 2 In one embodiment, the fibrous nonwoven layer of the first layer of the carpet primary backing can have an air permeability of up to 4000 l / m 2 In one embodiment, the fibrous nonwoven layer of the first layer of the carpet primary backing can have an air permeability of up to 3000 l / m 2 In one embodiment, the fibrous nonwoven layer of the first layer of the carpet primary backing may have an air permeability of up to 2000 l / m 2 In one embodiment, the fibrous nonwoven layer of the first layer of the carpet primary backing can have an air permeability of up to 1000 l / m 2 The air permeability may be measured in accordance with ISO 9237:1995 in all cases.

[0062] In one embodiment, the nonwoven layer of fibers of the second layer and / or the third layer of the carpet primary backing has a fiber density of at least 5000 l / m 2 In one embodiment, the fibrous nonwoven layer of the second and / or third layer of the carpet primary backing may have an air permeability of at least 6500 l / m 2 In one embodiment, the fibrous nonwoven layer of the second and / or third layer of the carpet primary backing may have an air permeability of at least 8000 l / m2 In one embodiment, the fibrous nonwoven layer of the second and / or third layer of the carpet primary backing may have an air permeability of at least 9500 l / m 2 In one embodiment, the fibrous nonwoven layer of the second and / or third layer of the carpet primary backing may have an air permeability of at least 12000 l / m 2 The air permeability may be measured in accordance with ISO 9237:1995 in all cases.

[0063] This object is also solved by a tufted carpet comprising a primary carpet backing according to any of the previously described embodiments, pile yarns tufted into the primary carpet backing, an optional secondary carpet backing adjacent a side of the primary carpet backing that is not the carpet face, and / or an optional precoat and / or polymer coat.

[0064] Without being bound by theory, it is believed that the asymmetry in the air permeability of the primary carpet backing allows the precoat and / or polymer coat to diffuse through the third and second layers, which have higher air permeability. It is further believed that the lower air permeability of the first layer of the primary carpet backing allows the first layer to act as a barrier layer, preventing or at least inhibiting the diffusion of the precoat and / or polymer coat, thereby preventing or at least reducing latex bleeding.

[0065] In one embodiment, the secondary carpet backing can include a fibrous reinforcing layer that can be constructed from any suitable material that can provide reinforcement. There are several classifications of materials available, such as high elasticity materials, low shrinkage materials, and materials that are resistant to compression.

[0066] Without wishing to be bound by theory, it is believed that locating the secondary carpet backing immediately adjacent to the primary carpet backing further reduces edge curl and curling in the tufted carpet.

[0067] The reinforcing layer of the carpet secondary backing may be a nonwoven, woven, scrim, unidirectional fibrous layer, or knitted fabric.

[0068] In one embodiment, the reinforcing layer of the carpet secondary backing is a laid scrim, a woven scrim, or a unidirectional fibrous layer, the fibers of the unidirectional fibrous layer being aligned substantially parallel to one another in the machine direction, and in this regard, the fibers of the unidirectional layer of the carpet secondary backing are spaced from one another such that the fibers do not contact adjacent fibers of the unidirectional fibrous layer of the carpet secondary backing.

[0069] In one embodiment, the fibers of the unidirectional fibrous layer are spaced from one another at a constant distance throughout the length of the unidirectional fibrous layer.

[0070] In one embodiment, the reinforcing layer of the carpet secondary backing is made of high modulus fibers. The fibers may be composed of materials selected from the group including glass, carbon, basalt, high modulus, low shrinkage (HMLS) polyester, inorganic materials, aramids such as para-aramid (PPTA) and meta-aramid (MPTA), and ultra-high molecular weight polyethylene (UHMWPE).

[0071] In one embodiment, the carpet secondary backing comprises a composite of at least three layers including two nonwoven layers of fibers, the reinforcing layer being disposed between the two nonwoven layers of fibers, and the carpet secondary backing has a density of at least 1000 l / m 2 In one embodiment, the carpet secondary backing comprises a composite material of at least three layers including two nonwoven layers of fibers, the reinforcing layer being disposed between the two nonwoven layers of fibers, and the carpet secondary backing has an air permeability of at least 3000 l / m 2 In one embodiment, the carpet secondary backing comprises a composite material of at least three layers including two nonwoven layers of fibers, the reinforcing layer being disposed between the two nonwoven layers of fibers, and the carpet secondary backing has an air permeability of at least 5000 l / m 2In one embodiment, the carpet secondary backing comprises a composite of at least three layers including two nonwoven layers of fibers, the reinforcing layer being disposed between the two nonwoven layers of fibers, and the carpet secondary backing has an air permeability of at least 7000 l / m 2 In one embodiment, the carpet secondary backing comprises a composite of at least three layers including two nonwoven layers of fibers, the reinforcing layer being disposed between the two nonwoven layers of fibers, and the carpet secondary backing has an air permeability of at least 9000 l / m 2 In one embodiment, the carpet secondary backing comprises a composite of at least three layers including two nonwoven layers of fibers, the reinforcing layer being disposed between the two nonwoven layers of fibers, and the carpet secondary backing has an air permeability of at least 10500 l / m 2 In one embodiment, the carpet secondary backing comprises a composite material of at least three layers including two nonwoven layers of fibers, the reinforcing layer being disposed between the two nonwoven layers of fibers, and the carpet secondary backing has an air permeability of at least 12000 l / m 2 Air permeability is measured in accordance with ISO 9237:1995.

[0072] One or both of the nonwoven layers of the carpet secondary backing fabric may be up to 50 g / m 2 One or both of the fibrous nonwoven layers of the carpet secondary backing may have an average weight of up to 30 g / m 2 One or both of the fibrous nonwoven layers of the carpet secondary backing may have an average weight of up to 30 g / m 2 One or both of the fibrous nonwoven layers of the carpet secondary backing may have an average weight of up to 20 g / m 2 One or both of the fibrous nonwoven layers of the carpet secondary backing may have an average weight of up to 10 g / m 2 One or both of the fibrous nonwoven layers of the carpet secondary backing may have an average weight of up to 7 g / m 2 The composition may have an average weight of

[0073] In one embodiment, the average diameter of the fibers of one or both of the two nonwoven layers of the fibers of the secondary carpet backing is at least 30 μm. In one embodiment, the average diameter of the fibers of one or both of the two nonwoven layers of the fibers of the secondary carpet backing is at least 35 μm. In one embodiment, the average diameter of the fibers of one or both of the two nonwoven layers of the fibers of the secondary carpet backing is at least 40 μm. In one embodiment, the average diameter of the fibers of one or both of the two nonwoven layers of the fibers of the secondary carpet backing is at least 50 μm. In one embodiment, the average diameter of the fibers of one or both of the two nonwoven layers of the fibers of the secondary carpet backing is at least 60 μm.

[0074] One or both of the two nonwoven layers of fibers in the carpet secondary backing can include monocomponent fibers, two types of monocomponent fibers, and / or bicomponent fibers.

[0075] One or both nonwoven layers of the fibers of the carpet secondary backing can be manufactured by a variety of processes, such as a spunlaid process, an airlaid process, a wetlaid process, a meltblowing process, or a carded process.

[0076] In one embodiment, one or both nonwoven layers of the fibers of the carpet secondary backing are manufactured by a spunlaid process, and the fibers are manufactured from a thermoplastic polymer-based material. In the spunlaid process, the bonding of the fibers of the nonwoven layer of the first layer of fibers and / or the fibers of the nonwoven layer of the third layer of fibers can be performed by any suitable process, including calendaring, hydroentangling, needling, ultrasonic bonding, chemical bonding, and other thermal bonding methods, such as hot air bonding.

[0077] In one embodiment, one or both nonwoven layers of fibers of the carpet secondary backing comprise two monocomponent fibers comprising two chemically distinct thermoplastic polymer-based materials, the melting temperatures of the different thermoplastic polymer-based materials differing by at least 10° C. In one embodiment, the melting temperatures of the different thermoplastic polymer-based materials differing by at least 20° C. In one embodiment, the melting temperatures of the different thermoplastic polymer-based materials differing by at least 30° C. In one embodiment, the melting temperatures of the different thermoplastic polymer-based materials differing by at least 50° C.

[0078] In one embodiment, the fibers of one or both of the fibers of the fibrous nonwoven layers of the carpet secondary backing are bicomponent fibers of the concentric or eccentric core / sheath model, side-by-side model, segmented pie model, or islands-in-the-sea model.

[0079] In one embodiment, the fibers of one or both of the nonwoven layers of the fibers of the secondary carpet backing are bicomponent fibers of a concentric core / sheath model, the fibers being made of the same class of thermoplastic polymer-based materials or chemically distinct thermoplastic polymer-based materials.

[0080] The sheath of the bicomponent fibers of one or both nonwoven layers of the fibers of the carpet secondary backing may comprise a thermoplastic polymer-based material having a higher melting temperature than the thermoplastic polymer-based material of the core. The melting temperatures of the thermoplastic polymer-based material of the sheath and the thermoplastic polymer-based material of the core may differ by at least 10°C. The melting temperatures of the thermoplastic polymer-based material of the sheath and the thermoplastic polymer-based material of the core may differ by at least 20°C. The melting temperatures of the thermoplastic polymer-based material of the sheath and the thermoplastic polymer-based material of the core may differ by at least 30°C. The melting temperatures of the thermoplastic polymer-based material of the sheath and the thermoplastic polymer-based material of the core may differ by at least 50°C.

[0081] The thermoplastic polymer-based material of the fibers of both nonwoven layers of the fibers of the carpet secondary backing may be selected from the group including polyolefins such as polyethylene (PE) and polypropylene (PP); polyesters such as polyethylene terephthalate (PET), polytrimethylene terephthalate (PTT), polybutylene terephthalate (PBT), polyethylene naphthalate (PEN), polyethylene-1,2-furan dicarboxylate (PEF), and polylactic acid (PLA); polyamides such as polyamide 6,6 (PA6,6) and polyamide 6 (PA6); and copolymers and / or blends thereof.

[0082] In one embodiment, the fibers of both nonwoven layers of fibers comprise at least 50% by weight of thermoplastic material. In one embodiment, the fibers of both nonwoven layers of fibers comprise at least 75% by weight of thermoplastic material. In one embodiment, the fibers of both nonwoven layers of fibers comprise at least 85% by weight of thermoplastic material. In one embodiment, the fibers of both nonwoven layers of fibers comprise at least 95% by weight of thermoplastic material. In one embodiment, the fibers of both nonwoven layers of fibers comprise at least 97% by weight of thermoplastic material.

[0083] In this regard, the thermoplastic polymer-based materials may include additives such as flame retardants, colorants, fillers, fungicides, and / or antimicrobial agents.

[0084] Tufted carpet according to the present application can be made by tufting a primary carpet backing, applying a secondary carpet backing to the side of the tufted primary carpet backing that is not the carpet face, and applying a precoat into and / or onto the secondary backing from the side of the secondary carpet backing that is not facing the primary carpet backing, and optionally applying a polymeric coating.

[0085] The primary carpet backing may be a tufted composite material, but it is also possible for the layers of the primary carpet backing to be individual layers adjacent to one another, so that the layers of the primary carpet backing are fed individually into the tufting machine.

[0086] In one embodiment, the layers of the primary carpet backing are tufted as a composite material.

Claims

1. A material for a carpet primary backing comprising a structure of at least three layers, a first layer and a third layer comprising a fibrous nonwoven layer, a second layer comprising a fibrous reinforcing layer, said second layer being located between said first layer and said third layer, said nonwoven layer of fibre of said first layer having a maximum tensile strength of 8000 l / m2 measured according to ISO 9237:1995. ２ s, and the nonwoven layer of fibers of the third layer has an air permeability of at least 3500 l / m2 measured according to ISO 9237:1995. ２ - has an air permeability of s, and the nonwoven layer of fibers of the first layer has a lower air permeability than the nonwoven layer of fibers of the third layer; When tufted, the third layer is disposed on the tufting side; 13. A material, comprising: said nonwoven layer of fibers of said first layer having a weight greater than a weight of said nonwoven layer of fibers of said third layer.

2. The material of claim 1 , wherein the weight ratio of said first layer to said second layer is at least 60:

40.

3. 3. The material of claim 1 or 2, characterized in that the fibers of the first layer have an average diameter smaller than the average diameter of the fibers of the third layer.

4. 4. The material according to claim 3, characterized in that the fibers of the first layer have an average diameter of at most 50 μm and / or the fibers of the third layer have an average diameter of at least 30 μm.

5. 5. The material according to claim 1, characterized in that the nonwoven layer of fibers of the first layer and / or the nonwoven layer of fibers of the third layer comprise monocomponent fibers, two monocomponent fibers, and / or bicomponent fibers.

6. The material described in claim 1, characterized in that the nonwoven layer of fibers of the first layer and / or the nonwoven layer of fibers of the third layer contain filaments.

7. The material of claim 6, wherein the filaments are thermoplastic.

8. 8. The material of claim 1, wherein the reinforcing layer is a laid scrim, a woven scrim, or a unidirectional fibrous layer, the fibers of the unidirectional fibrous layer being aligned substantially parallel to each other in the machine direction.

9. 9. The material according to any one of claims 1 to 8, characterized in that the reinforcing layer is made of high modulus fibres or filaments composed of a material selected from the group comprising glass, carbon, basalt, rock wool, high modulus low shrinkage (HMLS) polyester, inorganic materials, aramid, and ultra-high molecular weight polyethylene (UHMWPE).

10. The nonwoven layer of fibers of the first layer has a fiber density of up to 7000 l / m ２ 10. The material according to claim 1, characterized in that it has an air permeability, measured according to ISO 9237:1995, of 0.001 s.

11. The air permeability of the nonwoven layer of fibers of the third layer, measured according to ISO 9237, is at least 5000 l / m ２ 11. The material according to claim 1, characterized in that s.

12. 12. A tufted carpet comprising the material of any one of claims 1 to 11, pile yarns and / or a polymeric coating tufted into the primary carpet backing.

13. 13. The tufted carpet of claim 12, further comprising a secondary carpet backing adjacent a surface of the primary carpet backing that is not a carpet surface.

14. The tufted carpet of claim 12 or 13, further comprising a precoat.

15. The tufted carpet of claim 13, wherein the secondary carpet backing includes a reinforcing layer.

16. The carpet secondary backing comprises a composite of at least three layers including two nonwoven layers of fibers, the reinforcing layer being disposed between two spunbond nonwoven layers of fibers, and the carpet secondary backing has a fiber tensile strength of at least 1000 l / m2 as measured in accordance with ISO 9237:1995. ２ 16. The tufted carpet according to claim 15, characterized in that it has an air permeability of .s.

17. 17. The tufted carpet of claim 16, wherein the fibers of the two nonwoven layers of the fibers of the carpet secondary backing have an average diameter of at least 30 microns.

18. 18. A method for producing a tufted carpet according to any one of claims 12 to 17, by tufting a primary carpet backing, applying a secondary carpet backing to the side of the tufted primary carpet backing that is not the carpet face, and applying a precoat into and / or onto the secondary backing from the side of the secondary carpet backing that does not face the primary carpet backing.

19. 20. A method for producing a tufted carpet according to claim 18, characterized by applying a polymer coating.