Tufted carpet and backing therefore

A PET-based tufted carpet with a consolidated primary backing and thermobonded PET yarns addresses the structural integrity issues of high melting yarns, achieving stable and lightweight carpets suitable for automotive applications through a protected thermobonding process.

US20260168148A1Pending Publication Date: 2026-06-18CARL FREUDENBERG KG
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Patent Information

Authority / Receiving Office
US · United States
Patent Type
Applications(United States)
Current Assignee / Owner
CARL FREUDENBERG KG
Filing Date
2024-12-13
Publication Date
2026-06-18

AI Technical Summary

⚠Technical Problem

Existing methods for thermobonding high melting temperature yarns like PET in tufted carpeting, such as those used in automotive applications, face challenges as they often damage the primary backing due to the difference in melting temperatures, leading to structural integrity issues.

⚗Method used

A tufted carpet design using a primary backing composed of PET filaments and a lower melting polymer material, consolidated with a binder, where the backloops of PET yarns are thermobonded at a temperature that protects the primary backing from damage, ensuring stability and adhesion without additional adhesives.

🎯Benefits of technology

The method allows for high mechanical and thermal stability of PET yarn tufted carpets, suitable for molding, while maintaining a lightweight and efficient production process, without the need for additional adhesives, thus enhancing product integrity and ease of processing.

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Abstract

A tufted carpet including a primary backing which includes a spunbond nonwoven which includes polyethylene terephthalate (PET) filaments and a lower melting polymer material which is a filament forming material. The spunbond nonwoven is thermobonded by the lower melting polymer material. The spunbond nonwoven is further consolidated with a binder. The tufted carpet further includes tufts of yarn from polyethylene terephthalate (PET) which are sewn through the primary backing such that the piles of yarn are on a first surface and backloops of yarn are on a second surface of the primary backing. The backloops of yarn are thermobonded to the primary backing.
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