Carpet comprising a carbon-negative material

Abstract

Described herein are carpets having components, such as layers, with a particulate carbon-negative material. Also described herein are methods of making carpets having components, such as layers, with a particulate carbon-negative material.

Description

CARPET COMPRISING A CARBON-NEGATIVE MATERIALCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 552.395 filed February 12, 2024, the entirety of which is hereby incorporated by reference herein for all purposes.BACKGROUND

[0002] Most conventional carpets have a primary backing material with yam tufts in the form of cut or uncut loops extending upwardly from the backing to form a pile surface. In the case of tufted carpets, the yam is inserted into a primary’ backing material by tufting needles and a binder (carpet coating) is applied thereto. In the case of non-tufted or bonded pile carpets, the fibers are embedded and actually held in place by’ the binder composition. In both cases, the carpet construction can also include a secondary' backing material bonded to the primary backing. The secondary backing material provides extra padding to the carpet, absorbs noise, adds dimensional stability and often functions as a thermal insulator. Similar techniques are used in both the preparation of continuous (rolled) carpets as well as carpet tiles.

[0003] An important characteristic of carpet is the ability to exhibit good dimensional stability even when the carpet is exposed to moisture. Absorption of moisture can cause lateral grow th in the tiles, which, if occurring after installation, can result in enough lateral force to induce buckling of the installation at the seams (presenting as "curl"). This can lead to major issues in carpet tile installation and expensive repair claims. Accordingly, there remains a need for carpet materials which can mitigate unwanted curl.

[0004] Furthermore, global climate goals which limit global temperature rises to less than 2 °C by the end of the 21stcentury includes reducing greenhouse gases from the atmosphere. Carbon dioxide. CO2, is a greenhouse gas. Carbon-negative materials can absorb CO2 from the atmosphere. There is a need for carpet materials that provide a more environmentally friendly, net carbon-negative product, while maintaining desired performance characteristics, such as dimensional stability.

[0005] These needs and others are met by the disclosed carpets and methods herein.SUMMARY

[0006] Provided herein are carpets that contain an adhesive layer comprising an adhesive composition, wherein the adhesive composition comprises a particulate carbon-negative material. Also provided are methods of making the same.

[0007] In one aspect, disclosed herein are carpets comprising: a) a primary backing material having a face side and an opposing back side; b) a plurality of fibers attached to the primary backing material and extending from the face side of the primary backing material and exposed at the opposing back side of the primary backing material; c) a precoat layer having a face side and an opposing back side, wherein the face side of the precoat layer is attached to the opposing back side of the primary backing material, d) an adhesive layer having a face side and an opposing back side, wherein the face side of the adhesive layer is attached to the opposing back side of the precoat layer, wherein the adhesive layer comprises an adhesive composition comprising: i. a thermoplastic polyolefin; and ii. from about 0.1 % to about 75 % by weight of a particulate carbon-negative material; e) a reinforcing layer having a face side and an opposing back side, wherein the face side of the reinforcing layer is attached to the opposing back side of the adhesive layer; and f) a secondary backing material having a face side and an opposing back side, wherein the face side of the secondary backing material is attached to the opposing back side of the reinforcing layer, wherein the secondary backing material comprises a thermoplastic polyolefin.

[0008] In one aspect, disclosed herein are carpets comprising: a) a primary backing material having a face side and an opposing back side; b) a plurality of fibers attached to the primary backing material and extending from the face side of the primary backing material and exposed at the opposing back side of the primary backing material; c) an adhesive layer having a face side and an opposing back side, wherein the face side of the adhesive layer is attached to the opposing back side of the primary backing material, wherein the adhesive layer comprises an adhesive composition comprising: i. a thermoplastic polyolefin; and ii. from about 0.1 % to about 75 % by weight of a particulate carbon-negative material; d) a reinforcing layer having a face side and an opposing back side, wherein the face side of the reinforcing layer is attached to the opposing back side of the adhesive layer; and e) a secondary backing material having a face side and an opposing back side, wherein the face side of the secondary backing material is attached to the opposing back side of the reinforcing layer, wherein the secondary' backing material comprises a thermoplastic polyolefin.

[0009] In one aspect, disclosed herein are carpets comprising: a) a primary' backing material having a face side and an opposing back side; b) a plurality’ of fibers attached to theprimary backing material and extending from the face side of the primary backing material and exposed at the opposing back side of the primary backing matenal; c) a precoat layer having a face side and an opposing back side, wherein the face side of the precoat layer is attached to the opposing back side of the primary backing material; d) an adhesive layer having a face side and an opposing back side, wherein the face side of the adhesive layer is attached to the opposing back side of the precoat layer, wherein the adhesive layer comprises an adhesive composition comprising: i. a thermoplastic polyolefin; and ii. from about 0.1 % to about 75 % by weight of a particulate carbon-negative material; and e) a reinforcing layer having a face side and an opposing back side, wherein the face side of the reinforcing layer is attached to the opposing back side of the adhesive layer.

[0010] In one aspect, disclosed herein are carpets comprising a) a primary backing material having a face side and an opposing back side; b) a plurality of fibers attached to the primary backing material and extending from the face side of the primary backing material and exposed at the opposing back side of the primary backing material; c) an adhesive layer having a face side and an opposing back side, wherein the face side of the adhesive layer is attached to the opposing back side of the primary backing material, wherein the adhesive layer comprises an adhesive composition comprising: i. a thermoplastic polyolefin; and ii. from about 0.1 % to about 75 % by weight of a particulate carbon-negative material; and d) a reinforcing layer having a face side and an opposing back side, wherein the face side of the reinforcing layer is attached to the opposing back side of the adhesive layer.

[0011] In another aspect, further disclosed herein is a method of making a carpet comprising: a) providing a primary backing material having a face side and an opposing back side, wherein the primary backing material comprises a plurality7of fibers attached to the primary7backing material and extending from the face side of the primary backing material and exposed at the opposing back side of the primary backing material; b) attaching a precoat layer having a face side and an opposing back side to the opposing back side of the primary backing material; c) attaching an adhesive layer having a face side and an opposing back side to the opposing back side of the precoat layer, wherein the adhesive layer comprises an adhesive composition comprising: i. a thermoplastic polyolefin; and ii. from about 0. 1 % to about 75 % by weight of a particulate carbon-negative material; d) attaching a reinforcing layer having a face side and an opposing back side to the opposing back side of the adhesive layer; and e) attaching a secondary backing material having a face side and an opposing back side to the opposing back side of the reinforcing layer, wherein the secondary7backing material comprises a thermoplastic material, thereby forming the carpet.

[0012] Additional aspects of the disclosed carpets and methods will be set forth, in part, in the detailed description, and claims which follow, and in part will be derived from the detailed description, or can be learned by practice of the disclosed carpets and methods. 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 disclosed carpets and methods.BRIEF DESCRIPTION OF THE FIGURES

[0013] These and other features of the aspects of the disclosed carpets and methods will become more apparent in the detailed description in which reference is made to the appended drawings wherein:

[0014] FIG. 1 depicts an exemplar}’ structure of a carpet disclosed herein.

[0015] FIG. 2 depicts a schematic illustration of an exemplary aspect of the method of making a carpet.DETAILED DESCRIPTION

[0016] The present invention can be understood more readily by reference to the following detailed description, examples, drawings, and claims, and their previous and following description. However, before the present articles, devices, systems, and / or methods are disclosed and described, it is to be understood that inventions described and claimed herein are not limited to the specific 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.

[0017] The following description of the disclosed carpets and methods are provided as an enabling teaching of the invention in its best, currently known embodiment. To this end, those skilled in the relevant art will recognize and appreciate that many changes can be made to the various aspects of the disclosed carpets and methods, while still obtaining the beneficial results of the disclosed carpets and methods. It w ill also be apparent that some of the desired benefits of the present carpets and methods can be obtained by selecting some of the features of the disclosed carpets and methods without utilizing other features.Accordingly, those who work in the art will recognize that many modifications and adaptations to the disclosed carpets and methods are possible and can even be desirable incertain circumstances and are a part of the disclosed carpets and methods. Thus, the following description is provided as illustrative of the principles of the disclosed carpets and methods and not in limitation thereof.

[0018] In this specification and in the claims that follow, reference will be made to a number of terms, which shall be defined to have the following meanings:

[0019] Throughout the description and claims of this specification the word “comprise’' and other forms of the word, such as “comprising” and “comprises.” means including but not limited to, and is not intended to exclude, for example, other additives, components, integers, or steps. Furthermore, it is to be understood that the terms comprise, comprising and comprises as they related to various aspects, elements and features of the disclosed carpets and methods also include the more limited aspects of “consisting essentially of’ and “consisting of.”

[0020] As used throughout, the singular forms “a,” “an” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “a layer” can include two or more such layers unless the context indicates otherwise.

[0021] Ranges can be expressed herein as from “about” one particular value, and / or to "about" another particular value. When such a range is 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 the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint.

[0022] As used herein, the terms “optional” or “optionally” mean that the subsequently described event or circumstance may or may not occur, and that the description includes instances where said event or circumstance occurs and instances where it does not.

[0023] As used herein, the term “substantially” means that the subsequently described event or circumstance completely occurs or that the subsequently described event or circumstance generally, typically, or approximately occurs. For example, when the specification discloses that substantially all of an agent is released, a person skilled in the relevant art would readily understand that the agent need not be completely released. Rather, this term conveys to a person skilled in the relevant art that the agent need only be released to an extent that an effective amount is no longer unreleased.

[0024] The carbon footprint of a product is a measure of the total greenhouse gases (GHGs) that are removed from the atmosphere or emitted to the atmosphere during the product's life cycle (e.g., creation, use, and disposal). Also referred to as net Global Warming Potential (GWP) emissions, the carbon footprint is measured in kilograms of carbon dioxide (CO2) equivalents per square meter (kg CO2 eq / m2). In determining GWP emissions. GHGs other than CO2 are converted to CO2 equivalents based on their radiative forcing effects over a period of one hundred years. A negative net GWP indicates that more GHGs are removed from the atmosphere than are emitted into the atmosphere during the life cycle of the product. As used herein, the term “carbon-negative material'’ refers to a material refers to a material that has a negative GWP (less than zero) for the cradle-to-gate stage, as defined in standard NEN-EN 15804:2012 Sustainability of construction works — Environmental Product Declarations — Core rules for the product category of construction products..

[0025] As used herein, the term “particulate carbon-negative material” refers to a carbon-negative material as defined herein, wherein the carbon-negative material is a plurality of particles having a mean particle size. The particles can be of a symmetrical, globular, spherical shape, or be of an irregular, asymmetric shape or form. Examples of shapes that the particles can be include, but are not limited to, spherical, spheroid, rodshaped. disk-shaped, pyramid-shaped, cube-shaped, cylinder-shaped, nanohelical-shaped, nanospring-shaped, nanoring-shaped, arrow-shaped, teardrop-shaped, tetrapod-shaped, prismshaped. any other suitable geometric or non-geometric shape, or any combination of shapes. The mean particle size of the plurality of particles may vary. In some embodiments, the mean particle size is from about 1 pm to 5 mm, 1 pm to 1 mm, 1 pm to 0.5 mm, 1 pm to 0. 1 mm, 1 pm to 50 pm, 1 pm to 10 pm, 1 pm to 5 pm, 5 pm to 2 mm, 5 pm to 1 mm, 5 pm to 0.5 mm, 5 pm to 0. 1 mm. 5 pm to 50 pm, 5 pm to 10 pm, 10 pm to 2 mm, 10 pm to 1 mm. 10 pm to 0.5 mm, 10 pm to 0.1 mm, 10 pm to 50 pm, 0.5 mm to 2 mm, 0.5 mm to 1 mm, 1 mm to 2 mm, 2 mm to 2.5 mm, 2 mm to 3 mm, 2 mm to 3.5 mm, 2 mm to 4 mm, 2 mm to 4.5 mm, 2 mm to 5 mm, or about 2 mm to 4 mm. As used herein, the term “attaching” refers to the joining of two materials, such as an adhesive layer and a precoat layer. For example, the phrase “attaching an adhesive layer to the opposing back side of the precoat layer” includes that the adhesive layer can be brought into direct physical contact with the opposing back side of the precoat layer. The phrase “attaching an adhesive layer to the back side of the opposing precoat layer” also includes that the adhesive layer can be brought into indirect physical contact with the opposing back side of the precoat layer, e.g. by way of one or more intervening layers, such as a reinforcing layer.

[0026] As used herein, the term 'w ater- absorbing particulate carbon-negative material’" refers to a particulate carbon-negative material that is characterized by a moisture regain of at least about 0.1 % after the material is dried at 221 °F for 1 hour, follow ed by exposure to 90 % relative humidity at 90 °F for 16 days. The water-absorbing carbon-negative material can have a moisture regain of, for example, at least 0.2 %. 0.3 %, 0.4 %, 0.5 %. 0.6 %, 0.7 %, 0.8 %, 0.9 % or about 1.0 % after exposure to 90 % R.H. for 16 days. Examples of waterabsorbing particulate carbon-negative materials include, but are not limited to, oolitic aragonite, carbon-negative precipitated calcium carbonate, a composite material comprising plastic matter and organic matter, and biochar. Examples of non-water-absorbing carbonnegative materials include, but are not limited to, carbon-negative polyethylene resins.

[0027] As used herein, the term "‘polyamide,” refers to any long-chain polymer in which the linking functional groups are amide (-CO-NH-) linkages. The term polyamide is further defined to include copolymers, terpolymers and the like as well as homopolymers and also includes blends of two or more polyamides.

[0028] As used herein, the term “polyolefin” refers to any class of polymers produced from a simple olefin (also called an alkene with the general formula CnEEn) as a monomer.

[0029] As used herein, “oolitic aragonite” refers to a naturally occurring form of aragonite. Oolitic aragonite can be recovered from the ocean floor as a particulate material. The oolitic aragonite can be recovered, for example, by dredging or otherwise removing oolitic aragonite from the ocean floor. The oolitic aragonite can include various sizes of the particulate material. The particulate material of oolitic aragonite can be a plurality of particles having a mean particle size. The particle size distribution (PSD) is herein presented by a D- value, such as a D50 value. The D50, the median, is defined as the particle diameter where half of the population of the plurality of particles has a size smaller than this value.

[0030] Particles of oolitic aragonite used herein can have a D50 value of, for example, from 1 pm to 2 mm, 1 pm to 1 mm, 1 pm to 0.5 mm, 1 pm to 0.1 mm, 1 pm to 50 pm. 1 pm to 10 pm, 1 pm to 5 pm, 5 pm to 2 mm, 5 pm to 1 mm, 5 pm to 0.5 mm, 5 pm to 0.1 mm, 5 pm to 50 pm, 5 pm to 10 pm, 10 pm to 2 mm, 10 pm to 1 mm, 10 pm to 0.5 mm, 10 pm to 0. 1 mm, 10 pm to 50 pm, 0.5 mm to 2 mm, 0.5 mm to 1 mm, or about 1 mm to 2 mm. . Oolitic aragonite particles can have a generally spherical, ellipsoid, or oval shape.

[0031] Carbon-negative precipitated calcium carbonate is a carbon CAPture and CONversion (CAPCON) product that can be made, for example, by the Carbon CaptureMachine (CCM). as described in McDonald et al.. A New. Carbon-Negative Precipitated Calcium Carbonate Admixture (PCC-A) for Low Carbon Portland Cements, McDonald et al.. Materials (Basel), 2019 Feb. 13, 12(4):554. The carbon-negative precipitated calcium carbonate can include various sizes of the particulate material. The particulate material of carbon-negative precipitated calcium carbonate can be a plurality of particles having a mean particle size. The particle size distribution (PSD) is herein presented by a D-value, such as a D50 value. The D50, the median, is defined as the particle diameter where half of the population of the plurality of particles has a size smaller than this value.

[0032] Particles of carbon-negative precipitated calcium carbonate used herein can have a D50 value of, for example, from 1 pm to 2 mm, 1 pm to 1 mm, 1 pm to 0.5 mm, 1 pm to 0. 1 mm, 1 pm to 50 pm, 1 pm to 10 pm, 1 pm to 5 pm, 5 pm to 2 mm, 5 pm to 1 mm, 5 pm to 0.5 mm, 5 pm to 0.1 mm, 5 pm to 50 pm, 5 pm to 10 pm, 10 pm to 2 mm, 10 pm to 1 mm, 10 pm to 0.5 mm, 10 pm to 0. 1 mm. 10 pm to 50 pm. 0.5 mm to 2 mm, 0.5 mm to 1 mm, or about 1 mm to 2 mm. . Carbon-negative precipitated calcium carbonate particles can have a generally spherical, ellipsoid, or oval shape.

[0033] As used herein, "‘composite material comprising plastic matter and organic matter” refers to a composite material wherein plastic matter and organic matter derived from, for example, waste, sorted waste, or unsorted waste material are mixed and heated. The composite material comprising plastic matter and organic matter is heated to a temperature of about 140 °C to 230 °C under shear forces such that the composite material comprising plastic matter and organic matter has a phase transition from a solid to a flowable state. The composite material comprising plastic matter and organic matter can be heated, for example, to a temperature of about 140 °C to 200 °C, 140 °C to 180 °C, 140 °C to 160 °C, 160 °C to 230 °C, 160 °C to 200 °C, 160 °C to 180 °C, 160 °C to 170 °C, 170 °C to 230 °C, 170 °C to 200 °C, or about 170 °C to 180 °C. The composite material comprising plastic matter and organic matter can be heated to, for example, about 140 °C, 150 °C, 160 °C, 170 °C, 180 °C, 190 °C, 200 °C, 210 °C, 220 °C, or about 230 °C. Such a process for forming a composite material comprising plastic matter and organic matter is disclosed in, for example. U.S.Patent Publication No. 2016 / 0075072A1, the disclosure of which is incorporated herein in its entirety by reference for its disclosure related to forming a composite material comprising plastic matter and organic matter.

[0034] Particles of the composite material comprising plastic matter and organic matter used herein can have a D50 value of, for example, from about 0.5 mm to about 10 mm, about0.5 mm to about 1 mm, 1 mm to 2 mm, 2 mm to 2.5 mm, 2 mm to 3 mm. 2 mm to 3.5 mm, 2 mm to 4 mm, 2 mm to 4.5 mm, 2 mm to 5 mm, or about 2 mm to about 4 mm.

[0035] As used herein, the term “biochar'’ refers to the solid material obtained from the pyrolysis of a biomass material (e.g., carbohydrate, cellulosic, protein-containing, and / or fatcontaining material, such as wood, agricultural residue, manure, and the like) under an atmosphere that is deficient in oxygen relative to normal air, or in the absence of oxygen / air. The atmosphere, for example, can comprise less than about 12 %, 11 %, 10 %, 9 %, 8 %, 7 %, 6 %, 5 %, 4 %, 3 %, 2 %. 1 %, or less than about 0.5 % oxygen during pyrolysis. The atmosphere can comprise from about 0.5 % to 12 %, 0.5 % to 10 %, 0.5 % to 9 %, 0.5 % to 5 %, 0.5 % to 3 %, 1 % to 12 %, 1 % to 9 %, 1 % to 5 %, 1 % to 3 %, 5 % to 12 %, 5 % to 9 %, or about 3 % to 12 % oxygen during pyrolysis.

[0036] Particles of biochar can have a D50 value of, for example, from about 0.2 mm to about 3 mm, 0.2 mm to 2.5 mm, 0.2 mm to 2.0 mm. 0.2 mm to 1.5 mm, 0.2 mm to 1.0 mm, 0.2 mm to 0.5 mm. 0.5 mm to 3 mm, 0.5 mm to 2.5 mm, 0.5 mm to 2.0 mm, 0.5 mm to 1.5 mm, 0.5 mm to 1 .0 mm, 1 .0 mm to 3 mm, 1.0 mm to 2.5 mm, 1 .0 mm to 2.0 mm, 1 .0 mm to 1.5 mm, 1.0 mm to 3.0 mm, 1.0 mm to 2.5 mm, 1.0 mm to 2.0 mm, 1.0 mm to 1.5 mm, or about 2.0 mm to 3.0 mm.

[0037] As used herein, the term “filler” refers to a material which can be optionally added to one or more components or materials being a part of the carpets disclosed herein, wherein the filler is a separate material from the particulate carbon-negative material disclosed herein. The filler is not a particulate carbon-negative material.A. CARPETS

[0038] In various aspects, the disclosure herein relates to carpets. In one aspect, and with reference to FIG. 1, the carpet 100 can comprise a primary backing material 105 having a face side 102 and an opposing back side 103, a plurality of fibers 110 are attached to the primary' backing material and extending from the face side 102 of the primary' backing material and exposed at the opposing back side 103 of the primary' backing material. The carpet also optionally comprises a precoat layer 120 having a face side 124 and an opposing back side 126, wherein the face side 124 of the precoat layer is attached to the opposing back side 103 of the primary' backing material, an adhesive layer 130 comprising an adhesive composition, wherein the adhesive layer has a face side 134 and an opposing back side 136, wherein the face side 134 of the adhesive layer is attached to the opposing back side 126 ofthe precoat layer. The carpet also comprises a reinforcing layer 140 having a face side 144 and an opposing back side 146, wherein the face side of the reinforcing layer is attached to the opposing back side of the adhesive layer. The carpet also optionally comprises a secondary7backing material 150 having a face side 154 and an opposing back side 156, wherein the face side of the secondary backing material is attached to the opposing back side of the reinforcing layer.

[0039] The adhesive layer comprises a particulate carbon-negative material. In a further aspect, the adhesive layer comprises a water-absorbing particulate carbon-negative material in a weight % that is higher than a weight % of a water-absorbing particulate carbon-negative material in the secondary backing material. Furthermore, a reinforcing layer is embedded between the adhesive layer and the secondary backing material. The secondary7backing layer serves as a barrier between the adhesive layer and the floor, preventing water absorption from a high-moisture subfloor. Even if the adhesive layer absorbs some water and grows laterally, the result is likely to be dome (i.e., the center of a face-up tile will rise slightly off the floor relative to the comers), rather than curl (i.e., the comers of a face-up tile will rise slightly off the floor relative to the center), since the secondary backing layer, which does not comprise water-absorbing material or comprises weight % of water-absorbing material being less than the weight % of water-absorbing material in the adhesive layer, will not grow. A slight amount of dome is desirable in a finished carpet tile, as opposed to curl, which can cause major issues in a carpet tile installation. Accordingly, the carpets disclosed herein can exhibit desired curl mitigation properties.

[0040] In some aspects, only the adhesive layer comprises a particulate carbon-negative material. In further aspects, both the adhesive layer and the optional precoat layer comprise a particulate carbon-negative material. In yet further aspects, both the adhesive layer and the optional secondary backing material comprise a particulate carbon-negative material. In a yet still further aspect, the adhesive layer, the precoat layer, and the secondary backing material comprise a particulate carbon-negative material.1. PRIMARY BACKING MATERIAL

[0041] The carpet disclosed herein comprises a primary7backing material. In one aspect, the primary backing material of the carpet can have a face side and an opposing back side.

[0042] In certain aspects, the primary backing material comprises a polyolefin, a polyester, a polyamide, or a combination thereof. The primary backing material can bewoven or non-woven. In certain aspects, the primary backing material can comprise nonwoven webs, or spunbonded materials. In some aspects, the primary backing material can comprise a combination of woven and non-woven materials. In some aspects, the primary backing material comprises a polyolefin polymer. In other aspects, the polyolefin polymer comprises polypropylene. In yet other aspects, the primary backing material is a slit film polypropylene sheet such as that sold by Propex or Synthetic Industries owned by Shaw Industries. In yet further aspects, the primary backing material can comprise polyester. In still further aspect, the primary backing material can comprise polyamide. In yet further aspects, the primary backing material can comprise a combination of polyamide and polyester. In the certain aspects, the polyamide is nylon. In some other aspects, the primarybacking material can comprise a woven or non-woven polyethylene terephthalate (PET). In yet other aspects, the primary backing material can comprise a woven or non-woven PET having a post-consumer and / or post-industrial content.

[0043] In certain aspects, the primary backing material is a spun-bond primary- backing material. The spun bond backing material can be produced by depositing extruded, spun filaments onto a collecting belt in a uniform random manner followed by bonding the fibers. The fibers are separated during the web laying process by air jets or electrostatic charges. The collecting surface is usually perforated to prevent the air stream from deflecting and carry ing the fibers in an uncontrolled manner. Bonding imparts strength and integrity to the web by applying heated rolls or hot needles to partially melt the polymer and fuse the fibers together. Since molecular orientation increases the melting point, fibers that are not highly draw n can be used as thermal binding fibers. In some aspect, the spun-bond primary- backing material can comprise a bi-component filament of a sheath-core type. In some aspects, the polymeric core can have a higher melting point than the polymeric sheath. In some aspects, the polymeric core can comprise polyester, aliphatic polyamides, polyphenylene oxide and / or copolymers or blends thereof. In yet other aspects, the polyester can comprise polyethylene terephthalate, polybutylene terephthalate, or polyparaphenylene terephthalamide. In yet other aspects, the polymeric core comprises polyethylene terephthalate. In further aspects, the sheath polymer can comprise a polyamide, polyethylene, or polyester. In yet further aspects, the sheath polymer comprises nylon. In still further aspects, the sheath-core primary backing material comprises a polyester as a core component and nylon as a sheath component. The exemplary sheath-core primary- backing material can be commercially available from Freudenberg. In yet other aspects, a polyester non-woven primary- backing material can be commercially available from Freudenberg or Kolon.2. FIBERS

[0044] The carpet disclosed herein comprises a plurality of fibers. The plurality of fibers are attached to the primary backing material. The plurality of fibers extend from the face side of the primary backing material. The plurality of fibers are also exposed at the opposing back side of the primary backing material.

[0045] In some aspects, the plurality7of fibers are present as yam. In other aspects, the plurality of fibers are present as separate fibers. In some aspects, the plurality of fibers form tufts. In some aspects, a portion of the plurality of the fibers are exposed at the back surface of the primary backing component. In yet other aspects, a portion of the plurality of the fibers are exposed at the back surface of the pri mary backing material in a form of back stitches.

[0046] In some aspects, the plurality' of fibers can comprise a polyamide, an olefin, or a polyester. In some aspects, the plurality of polyamide fibers comprise one or more of nylon 6, nylon 6,6, nylon 10, nylon 6,12, nylon 12, nylon 11, or any combination thereof. In other aspects, the plurality of polyamide fibers comprise nylon 6 or nylon 6,6. In yet other aspects, the plurality' of polyamide fibers are nylon 6. In a yet further aspect, the plurality of polyamide fibers are nylon 6,6.

[0047] In certain aspects, the plurality of fibers comprise a polyester. The term ■‘polyester fiber” as utilized herein, refers to the manufactured fiber in which the fiberforming substance is any long-chain synthetic polymer composed of at least 85% by weight of an ester of a substituted aromatic carboxylic acid, including but not restricted to substituted terephthalic units, p(-R-O-CO- CeEU-CO-O-ty and parasubstituted hydroxy-benzoate units, p(-R-O-CO-CeH4-O-)x. In some aspects, the plurality of the polyester fibers comprise polyethylene terephthalate (PET) homopolymers and copolymers, polybutylene terephthalate (PBT) homopolymers and copolymers, and the like, including those that contain comonomers such as cyclohexanedimethanol, cyclohexanedicarboxylic acid, and the like.

[0048] In yet further aspects, the plurality’ of fibers can comprise a polyolefin fiber. In some aspects, the polyolefins which can be used to produce the yam and fibers include, but are not limited to, polyethylene, polypropylene, both homopolymer and copolymers, poly(l- butene), poly(3-methyl-l-butene), poly(4- methyl- 1-pentene) and the like, as well as combinations or mixtures of two or more of the foregoing. In certain aspects, the plurality of the polyolefin fibers comprise polyethylene or polypropylene. In other aspects, the pluralityof the polyolefin fibers comprise polyethylene. In yet other aspects, the plurality of the polyolefin fibers comprise polypropylene.In yet further aspects, the plurality of fibers can further comprise natural fibers, acrylics, viscose, rayon, cellulose acetate, linen, silk, cotton, wool, or any combination thereof.In some aspects, the precoat layer is attached to the opposing back side of the primary backing material. In certain aspects, the precoat layer is applied to the opposing back side of the primary backing material. The precoat layer can be used to lock the plurality of fibers or tufts in place. In some aspects, the precoat layer can provide additional strength to the tufts (so- called tuft bind strength). In yet other aspects, the precoat layer can be used to substantially prevent any additional adhesive compositions from penetration through (the openings between) the plurality of fibers (the tufts) in the direction of the carpet top face.

[0049] As understood by one of ordinary skill in the art, the plurality of fibers can comprise any types or forms of fibers. For example, and without limitation, the plurality of fibers can comprise staple fibers or bulked continuous filament fibers.3. OPTIONAL PRECOAT LAYER

[0050] The carpet disclosed herein optionally comprises a precoat layer. The precoat layer has a face side and an opposing back side. When present, the face side of the precoat layer is attached to the opposing back side of the primary backing material. In some aspects, the carpet comprises a precoat layer. In further aspects, the carpet does not comprise a precoat layer.

[0051] In some aspects, the precoat layer comprises a particulate carbon-negative material. In a further aspect, the particulate carbon-negative material can be a waterabsorbing particulate carbon-negative material.

[0052] In some aspects, the precoat layer does not comprise a particulate carbonnegative material.

[0053] In certain aspects, exemplary and non-limiting particulate carbon-negative materials that can be present in the precoat layer can include oolitic aragonite, carbonnegative precipitated calcium carbonate, a composite material comprising plastic matter and organic matter, or biochar.

[0054] In some aspects, the precoat layer comprises a particulate carbon-negativematerial being oolitic aragonite. Aragonite is a natural orthorhombic polymorph of calcium carbonate, and differs from calcite in that is has an orthorhombic crystalline structure, a greater specific gravity (2.93 to 2.95 g / cm3as compared to 2.71 g / cm3for calcite), and less distinct cleavage than calcite. Oolitic aragonite is the only naturally renewable source of calcium carbonate that has a negative carbon footprint, as such being a particulate carbonnegative material. In some aspects, the oolitic aragonite is first screened to remove impurities such as shell fragments. In further aspects, the oolitic aragonite is subjected to grinding to yield smaller particles.

[0055] In such aspects when oolitic aragonite is present in the precoat layer, oolitic aragonite is present in an amount of from about 0. 1 % to about 60 % by weight of the precoat layer. Oolitic aragonite can be present in an amount of, for example, from about 0. 1 % to about 55 %, 0.1 % to 50 %, 0. 1 % to 45 %, 0. 1 % to 40 %, 0. 1 % to 35 %, 0. 1 % to 30 %, 0. 1 % to 20 %. 0. 1 % to 10 %. 0. 1 % to 5 %, 0. 1 % to 1 %, 1 % to 60 %, 1 % to 55 %, 1 % to 50 %, 1 % to 45 %, 1 % to 40 %, 1 % to 35 %, 1 % to 30 %, 1 % to 25 %, 1 % to 20 %, 1 % to 10 %, 5 % to 60 %, 5 % to 55 %, 5 % to 50 %, 5 % to 40 %, 5 % to 30 %, 5 % to 25 %, 5 % to 20 %, 10 % to 60 %, 10 % to 55 %, 10 % to 50 %, 10 % to 45 %, 10 % to 40 %, 10 % to 30 %, 10 % to 20 %, 20 % to 60 %, 20 % to 50 %, 20 % to 40 %, 20 % to 30 %, 30 % to 60 %, 30 % to 50 %, 30 % to 40 %. 40 % to 60 %, 40 % to 50 %, or about 50 % to about 60 % by weight of the precoat layer. Oolitic aragonite can be present in an amount of, for example, about 0.1 %, 0.5 %, 1 %, 5 %, 10 %, 15 %, 20 %, 25 %, 30 %, 35 %, 40 %, 45 %, 50 %, 55 %, or about 60 % by weight of the precoat layer.

[0056] In certain aspects, the precoat layer comprises a particulate carbon-negative material being carbon-negative precipitated calcium carbonate.

[0057] In certain aspects, the precoat layer comprises a particulate carbon-negative material being a composite material comprising plastic matter and organic matter.

[0058] In some aspects, the composite material comprising plastic matter and organic matter is formed by mixing while heating the organic matter and plastic matter under shear forces.

[0059] In such aspects when a composite material comprising plastic matter and organic matter is present in the precoat layer, the composite material comprising plastic matter and organic matter is present in an amount of from about 0.1 % to about 30 % by weight of theprecoat layer. A composite material comprising plastic matter and organic matter can be present in an amount of, for example, from about 0. 1 % to 25 %, 0. 1 % to 20 %, 0. 1 % to 15 %, 0.1 % to 10 %, 0.1 % to 5 %, 0.1 % to 1 %, 0.1 % to 0.5 %, 0.5 % to 30 %, 0.5 % to 25 %, 0.5 % to 20 %, 0.5 % to 15 %, 0.5 % to 10 %, 0.5 % to 5 %, 1 % to 30 %, 1 % to 25 %, 1 % to 20 %, 1 % to 15 %, 1 % to 10 %, 1 % to 5 %. 5 % to 30 %. 5 % to 25 %. 5 % to 20 %. 5 % to 15 %, 5 % to 10 %, 10 % to 30 %, 10 % to 25 %. 10 % to 20 %, 10 % to 15 %, 15 % to 30 %, 15 % to 25 %, 15 % to 20 %, 20 % to 30 % , 20 % to 25 %, or about 25 % to 30 % by weight of precoat layer. A composite material comprising plastic matter and organic matter can be present in an amount of, for example, about 0. 1 %. 0.5 %, 1 %, 5 %, 10 %, 15 %, 20 %, 25 %. or about 30 % by weight of the precoat layer.

[0060] In certain aspects, the precoat layer comprises a particulate carbon-negative material being biochar.

[0061] Pyrolysis of biomass to obtain biochar can be performed at a temperature of 1000 °C or less, 900 °C or less, 800 °C or less, 700 °C or less, 600 °C or less, 500 °C or less, 400 °C or less, 300 °C or less, or 200 °C or less. Pyrolysis can be performed at a temperature of from about 200 °C to about 1000 °C, about 200 °C to about 900 °C, about 200 °C to about 800 °C, about 300 °C to about 1000 °C, about 300 °C to about 900 °C, about 300 °C to about 800 °C, about 300 °C to about 700 °C, about 400 °C to about 1000 °C, about 400 °C to about900 °C, about 400 °C to about 800 °C, about 400 °C to about 700 °C, about 500 °C to about1000 °C, about 500 °C to about 900 °C, about 500 °C to about 800 °C, about 500 °C to about 700 °C, about 500 °C to about 600 °C. about 600 °C to about 1000 °C, about 600 °C to about900 °C, about 600 °C to about 800 °C, or about 600 °C to about 700 °C.

[0062] Prior to pyrolysis, the biomass can be sorted according to particle size or dried to reduce moisture. However, unlike the materials used to form activated charcoal, which is a net carbon positive material, the biomass used to form the biochar disclosed herein is not subjected to chemical treatment via acid, base, or salt. Likewise, the biochar is not chemically treated after pyrolysis or subjected to oxidation. The biochar disclosed herein does not comprise activated carbon or activated charcoal, which are inherently carbon positive materials and are energy intensive to produce.

[0063] In some aspects, the precoat layer comprises a carbon-negative polymer resin. In some aspects, the precoat layer comprises a carbon-negative polyethylene resin. In a furtheraspect, the carbon-negative polyethylene resin is not a water-absorbing carbon-negative material.

[0064] In some aspects, the precoat layer comprises a thermoplastic dispersion. In yet other aspects, the precoat layer comprises a polyolefin dispersion.

[0065] In still further aspects, the precoat layer comprises an aqueous precoat material. In some exemplary aspects, the aqueous precoat material can, for example, be added as a dispersion or as an emulsion. In certain aspects, a precoat 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 polymer, or mixtures thereof). In some aspects, the precoat layer can comprise a latex. It is further contemplated that the precoat material in the precoat layer can be selected from a group comprising, without limitation, an EVA hotmelt, a vinyl acetate ethylene (VAE) emulsion, carboxylated styrene-butadiene (XSB) latex copolymer, a styrene- butadiene resin (SBR) latex, a BDMMA latex, an acrylic latex, an acrylic copolymer, a styrene copolymer, butadiene acrylate copolymer, a polyolefin hotmelt. polyurethane and / or emulsions, and any combination thereof.

[0066] In some aspects, where precoat layer comprises a latex, the latex further comprises a carboxylated styrene-butadiene (XSB) latex copolymer, a styrene- butadiene resin (SBR) latex, a BDMMA latex, an acrylic latex, an acrylic copolymer, a styrene copolymer, or a combination thereof.

[0067] In some aspects, where the thermoplastic dispersion is present, the thermoplastic dispersion can have a total solids content in the range of from about 30 to about 80 %, including exemplary values of about 35 %, about 40 %, about 45 %, about 50 %, about 55 %, about 60 %, about 65 %, about 70 %, and about 75 %. In some other aspects, the thermoplastic dispersion can have a total solids content in the range from about 30 % to about 60 %, from about 40 % to about 50 %, or from about 45 % to about 55 %. It is understood that a total solids content is controlled by an amount of a liquid medium present in the thermoplastic dispersion. In some exemplary aspects, the liquid medium comprises water. In other aspects, the liquid medium can comprise a non-aqueous liquid. In some aspects, the non-aqueous liquid can comprise organic solvents. In some aspects, the organic solvents can comprise any polar organic solvents. In yet other aspects, the organic solvents can compriseany non-polar organic solvents.

[0068] In some other aspects, any precoat layer disclosed herein can have a total solids content in the range of from about 50 % to about 90 %, including exemplary value of about 55 %, about 60 %, about 65 %, about 70 %, about 75 %, about 80 %, and about 85 %. In yet other aspects, the precoat layer can have a total solids content in the range from about 40 % to 60 %, or from about 65 % to about 85 %.

[0069] In some aspects, the thermoplastic dispersion present in the precoat layer is a polyolefin dispersion. In certain aspect, the thermoplastic dispersion can be present in an amount in the range of from about 20 % to about 90 % by weight of the dispersion, including exemplary values of about 25 %, about 30 %, about 35 %, about 40 %, about 45 %, about 50 %, about 55 %, about 60 %, about 65 %, about 70 %, about 80 %, and about 85 %. In yet other aspects, the thermoplastic dispersion can be present in an amount in the range from about 25 % to about 50 %, or from about 30 % to about 70 %. In yet other aspects, the polyolefin dispersion is present in an amount in the range from about 25 % to about 50 %, or from about 40 % to about 70 %.

[0070] In yet other aspects, the thermoplastic dispersion precoat layer is substantially free of latex. In still further aspects, the thermoplastic dispersion precoat layer is substantially free of ethy lene acrylic acid (EAA), or ethylene vinyl acetate (EVA). In yet other aspects, the thermoplastic dispersion precoat layer is substantially free of an EVA hotmelt, a vinyl acetate ethylene (VAE) emulsion, carboxylated styrene-butadiene (XSB) latex copolymer, a styrenebutadiene resin (SBR) latex, a BDMMA latex, an acrylic latex, an acrylic copolymer, a styrene copolymer, butadiene acry late copolymer, polyurethane, or any combination thereof.

[0071] In certain aspects, the thermoplastic dispersion comprises a dispersion of a propylene block copolymer, ethylene block copolymer, or a combination thereof. In some aspects, the thermoplastic dispersion can comprise more than one polyolefin. In certain aspects, the polyolefins can comprise alpha-olefin polymers and copolymers, such as ethylene alpha-olefin copolymers and propylene alpha-olefin copolymers. In some aspects, the thermoplastic dispersion can comprise ethylene-propylene-diene terpolymers. In certain aspects, the polyolefins can include high density' polyethylenes ("HDPE"), heterogeneously branched linear low density' polyethylenes ("LLDPE"), heterogeneously branched ultra low linear density’ polyethylenes ("ULDPE"), homogeneously branched, linear ethylene / alpha- olefin copolymers ("HBPE"); homogenously branched, substantially linear ethylene / alpha-olefin copolymers ("SLEP"); high pressure, free radical polymerized ethylene polymers and copolymers such as low density polyethylenes. ("LDPE"). In some aspects, the thermoplastic comprise polymeric units derived from one or more alpha-olefin comonomers. Exemplary comonomers can include C2, and C4 to C10 alpha-olefins, for example: C2, C4, Ce, and Cs alpha-olefins.

[0072] In some aspects, the polyolefin dispersions can comprise a polymer blend. In some embodiments, the blend may comprise two different Ziegler-Natta polymers. In other embodiments, the blend may comprise a Ziegler- Natta polymer and a metallocene polymer. In still other embodiments, the blend may comprise two different metallocene polymers.

[0073] In some further aspects, the precoat layers described herein can further comprise a stabilizing agent, such as a surfactant, a poly mer having a polar group as either a comonomer or a grafted monomer, and mixtures thereof. Examples of surfactants that can be useful as a stabilizing agent include cationic surfactants, anionic surfactants, and no-ionic surfactants. In certain aspects, where thermoplastic dispersions are present, an optional base can be included in the thermoplastic dispersion. Examples of bases that can be used include alkaline metals and alkaline earth metals, inorganic amines; oxides, hydroxide and hydride of alkaline metals and alkaline earth metals; and weak acid salts of alkaline metals and alkaline earth metals.

[0074] In some exemplar}’ aspects, the thermoplastic dispersions described herein are commercially available from the DOW Chemical Company, under the tradename HYPOD™.

[0075] In some aspects, the precoat layer can further comprise a filler. In certain aspects, the filler can be present in an amount from about 20 % to about 90 % by weight of any precoat layer described herein, including exemplary values of about 25 %, about 30 %, about 35 %, about 40 %, about 45 %, about 50 %, about 55 %, about 60 %, about 65 %, about 70 %, about 75 %, about 80 %, and about 85 %. In yet other aspects, the filler can be present in any amount from about 25 % to about 50 %, from about 45 % to about 85 %. or from about 55 % to about 90 %.

[0076] In yet other aspects, the filler can be present in an amount from about 100 to about 700 dry' parts based on 100 dry' parts of the thermoplastic dispersion or the latex, including exemplary values of about 150, about 200, about 250, about 300. about 350, about 400, about 450, about 500, about 550, about 600, and about 650 dry parts based on 100 dryparts of thermoplastic dispersion or the latex. It is understood that the filler can be present in any amount between any two foregoing values. In still further aspects, the filler can be present in an amount from about 150 to about 550 dry parts based on 100 dry parts of the thermoplastic composition or the latex, or from about 150 to about 350 dr ' parts based on 100 dry parts of the thermoplastic composition or the latex.

[0077] In some aspects, the filler can be derived from any recycled compositions. In yet other aspects, the filler can be derived from recycled asphalt content. In yet other aspects, the filler can be derived from any recycled composition that can provide a substantial amount of inorganic material that can be utilized as a filler. In some aspects, the filler comprises a recycled calcium carbonate in a different form than oolitic aragonite. In some aspects, the filler comprises a recycled calcium carbonate in a different form than oolitic aragonite and carbon-negative precipitated calcium carbonate. In some aspects, the filler comprises a recycled calcium carbonate in a different form than carbon-negative precipitated calcium carbonate.

[0078] In certain aspects, exemplary' and non-limiting fillers that can be present in the precoat layer can include calcium carbonate, flyash. residual by products from the depolymerization of Nylon 6 (also referred to as ENR co-product), aluminum trihydrate, talc, nano-clay, barium sulfate, barite, barite glass fiber, glass powder, glass cullet, metal powder, alumina, hydrated alumina, clay, magnesium carbonate, calcium sulfate, silica, glass, fumed silica, carbon black, graphite, cement dust, feldspar, nepheline, magnesium oxide, zinc oxide, aluminum silicate, calcium silicate, titanium dioxide, titanates, glass microspheres, chalk, calcium oxide, and any combination thereof. As defined, the filler is not a particulate carbonnegative material. Thus, when the filler is calcium carbonate it is in a different form than oolitic aragonite. In some aspects, when the filler is calcium carbonate it is in a different form than oolitic aragonite and carbon-negative precipitated calcium carbonate. In some aspects, when the filler is calcium carbonate it is in a different form than carbon-negative precipitated calcium carbonate.

[0079] In some aspects, the filler can comprise a kaolin clay. In yet other aspects, the kaolin clay can comprise a plurality of particles, wherein each of the plurality' of particles is surface modified. In some aspects, the each of the plurality of particles is surface modified by calcination. In yet other aspects, the each of the plurality' of particles is surface-modified by utilizing a coupling agent, for example and without limitation silane. In some other aspects, silane coupling agent can be functionalized by mercapto-, polysulfide-, amino- and vinyl-groups. It is further understood that any known in the art coupling agent can be used to surface modify kaolin particles. In yet some other aspects, the each of the plurality of particles can be surface modified both by calcination and use of a coupling agent.

[0080] In some aspects, the filler comprises a kaolin clay slurry. In these aspects, the kaolin clay slurry can have a total solids content from about 50 % to about 90%, including exemplary values of about 55 %, about 60 %, about 65 %, about 70 %, about 75 %, about 80 %, and about 85 %. In yet other aspects, the kaolin clay slurry has a total solids content from about 55% to about 85 %, or about 60 % to about 80%. It is understood that a total solids content is controlled by an amount of a liquid medium present in the kaolin clay slurry. In some exemplary aspects, the liquid medium comprises water. In yet other aspects, any liquid medium known in the art and capable of making a dispersion or a slurry with the kaolin clay can be utilized. In some aspects, liquid medium can be nonaqueous. In yet other aspects, the slurry’ can comprise plasticizers.

[0081] In certain aspects, the filler comprises calcium carbonate in a different form than oolitic aragonite, carbon-negative precipitated calcium carbonate, and kaolin clay slurry. In some aspects, the calcium carbonate in a different form than oolitic aragonite, carbonnegative precipitated calcium carbonate, and kaolin clay slurry are present in the fillers in a substantially equal amount when measured in dry parts based on 100 dry parts of the thermoplastic dispersion. In other aspects, the calcium carbonate in a different form than oolitic aragonite, carbon-negative precipitated calcium carbonate, and kaolin clay slurry are present in the filler in any ratio when measured in dry parts based on 100 dry parts of the thermoplastic dispersion or the latex. In some aspects, the calcium carbonate in a different form than oolitic aragonite, carbon-negative precipitated calcium carbonate, and kaolin clay slurry' are present in the filler in a ratio of 1: 1, 1:2, 1:3, 1:4, 1:5, 1:6, 1 :7, 1 :8, 1 :9, 1 : 10, 10:1. 9: 1, 8: 1, 7: 1, 6: 1. 5: 1, 4: 1, 3: 1. or 2: 1, when measured in dry parts based on 100 dry parts of the thermoplastic dispersion or the latex.

[0082] In some aspects, the kaolin clay slurry present in the filler comprises a plurality' of particles having a particle size from about 0. 1 pm to about 5 pm, including exemplary values of about 0.2 pm, about 0.3 pm, about 0.4 pm, about 0.5 pm, about 0.6 pm, about 0.7 pm, about 0.8 pm, about 0.9 pm, about 1.0 pm, about 1.5 pm, about 2.0 pm, about 2.5 pm, about 3.0 pm, about 3.5 pm, about 4.0 pm, and about 4.5 pm.

[0083] In certain aspect, the precoat layer can further comprise one or more flameretardants. Exemplary flame retardants that can be present in the precoat layer include, without limitation, organo-phosphorous 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, silicon dioxide, calcium carbonate, resourcinol bis-(diphenyl phosphate), brominated latex base, antimony trioxide, strontium borate, strontium phosphate, monomeric N-alkoxy hindered amine (NOR HAS), triazine and its derivatives, high aspect ratio talc, phosphated esters, organically modified nanoclays and nanotubes, non-organically modified nanoclays and nanotubes, ammonium polyphosphate, polyphosphoric acid, ammonium salt, triaryl phosphates, isopropylated triphenyl phosphate, phosphate esters, magnesium hydroxide, zinc borate, bentonite (alkaline activated nanoclay and nanotubes), organoclays, aluminum trihydrate (ATH), azodicarbonamide, diazenedicarboxamide, azodicarbonic acid diamide (ADC), triaryl phosphates, isopropylated triphenyl phosphate, triazine derivatives, alkaline activated organoclay and aluminum oxide. Any desired amount of flame retardant can be used in the precoat layer and the selection of such amount will depend, in part, upon the particular flame retardant used, as well as the desired level of flame retardance to be achieved. Such amounts can be readily determined through no more than routine experimentation.

[0084] In still a further aspect, the precoat layer can further comprise other ingredients. For example, a surfactant can be included in the precoat layer. Suitable surfactants can include, for example and without limitation, nonionic, anionic, cationic and fluorosurfactants. In certain aspects, the surfactant is present in an amount from greater than 0 % to about 5 % by weight based on the total w eight of the precoat layer. In yet other aspects, the surfactant is present in exemplary' amounts such as about 0.01 %, about 0.05 %, about 0.1 %, about 0.5 %, about 1 %, about 1.5 %, about 2 %, about 2.5 %, about 3 %, about 3.5 %. about 4 %, and about 4.5 %. In yet other aspects, the surfactant can be present in an amount from greater than 0 % to about 4 %, or from about 0.05% to about 4.5 %.

[0085] In another example, the precoat layer can further comprise a rheology' agent, a defoaming agent, and / or a dispersion enhancer. In some aspect, the rheology agent comprises a thickener. In these aspects, the thickener helps to provide a suitable viscosity to the dispersion. For example, the thickener can exemplarily comprise sodium and ammonium salts of polyacrylic acids. In some aspects, the rheology' agent is present in an amount from greater than 0 % and about 5 % based on the total weight of the precoat layer, includingexemplary values of about 0.01 %, about 0.05 %, about 0.1 %, about 0.5 %, about 1 %, about1.5 %, about 2 %, about 2.5 %, about 3 %, about 3.5 %, about 4 %, and about 4.5 %. In yet other aspects, the rheology agent can be present in an amount from greater than 0 % to about 2 %, or from about 0.05% to about 4 %.

[0086] In other aspects, the defoaming agent can, without limitation, be a non-silicone defoaming agent and is present in an amount greater than 0 % and about 5.0 % based on the total weight of the precoat layer, including exemplary' values of about 0.01 %, about 0.05 %, about 0.1 %, about 0.5 %, about 1 %, about 1.5 %, about 2 %, about 2.5 %. about 3 %, about3.5 %, about 4 %, and about 4.5 %. In yet other aspects, the defoaming agent can be present in an amount from greater than 0% to about 4 %, or from about 0.05% to about 4.5 %. An exemplified dispersion enhancer can be a fumed silica that acts as a compatibilizer for the dispersion. In these aspects, the fumed silica can be present at between about 0. 1 and about 0.2 % percent based on the total weight of the precoat layer.

[0087] In yet other aspects, the precoat layer can comprise a surfactant and a rheology' agent. In the aspects where both the surfactant and the rheology agents are present, the amounts of the surfactant and the rheology’ agent can be in any value from any range described above.

[0088] In some other aspects, the precoat layer can further comprise wax. In some aspects, wax comprises petroleum based waxes, animal based waxes, plant based waxes, or any combination thereof. In some aspects, wax present in the precoat layer as a fine homogeneous dispersion in a liquid medium. In some aspects, the liquid medium is water. In another aspect, the liquid medium is any medium know n in the art capable of forming a dispersion with wax. Without wishing to be bound by any theory, it is hypothesized that wax presence in the precoat layer can impart some hydrophobicity to reduce moisture or spill penetration through the product.

[0089] In some aspects, the precoat layer can be substantially free of a tackifier. In yet other aspects, the precoat layer can comprise tackifier.

[0090] In some aspects, the precoat layer comprising the thermoplastic dispersions can exhibit stable properties both when cold blended or hot blended. As used herein, a “cold blend” precoat layer refers to a precoat layer that has been blended at mild refrigeration. In some exemplary aspects, the cold blend precoat layer refers to the precoat layer blended at atemperature from about 30 ° F to about 50 ° F, including exemplary values of about 35 ° F, about 400F, and about 450F. In some aspects, the precoat exhibits stable properties when stored at mild refrigeration. In yet other aspects, the precoat exhibits stable properties when stored in a cold climate.

[0091] As used herein, a ‘‘hot blend” precoat layer refers to a precoat layer has been blended at mildly elevated temperatures. In some exemplary aspects, the hot blend layer refers to the precoat layer blended at a temperature from about 800F to about 1500F, including exemplary values of about 85 ° F, about 900F, about 100 ° F, about 105 ° F, about 110 ° F, about 1150F, about 120 ° F. about 1250F, about 130 ° F. about 1350F, about 140 ° F, and about 145 ° F. In some aspects, the precoat exhibits stable properties when stored at elevated temperatures. In yet other aspects, the precoat exhibits stable properties when stored in a w arm climate.

[0092] In some aspects, the precoat layer, cold or hot blended can exhibit a viscosity in the range from about 2,000 to about 15,500 cP when measured at 20 rpm, including exemplary values of about 2,500 cP, about 3,000 cP, about 3,500 cP, about 4,000 cP. about 4,500 cP. about 5,000 cP, about 5,500 cP, about 6,000 cP, about 6,500 cP, about 7.000 cP, about 7,500 cP, about 8,000 cP, about 8,500 cP, about 9,000 cP, about 9,500 cP, about 10,000 cP, about 10,500 cP, about 11,000 cP, about 11,500 cP, about 12,000 cP, about 12,500 cP, about 13,000 cP, about 13,500 cP, about 14,000 cP, about 14,500 cP, and about 15,000 cP. In yet other aspects, the precoat layer exhibits a viscosity from about 2,500 cP to about 4,500 cP. or from about 3,500 cP to about 5.500 cP when measured at 20 rpm.

[0093] In yet other aspects, the precoat layer comprising the thermoplastic dispersion can exhibit a viscosity after a storage period of at least 3 days, at least one week, at least 2 weeks, or at least one month that is within + / - 20% of an initial viscosity measured before the storage period. In yet other aspects, the precoat layer can exhibit a viscosity after a storage period of at least 3 days, at least one w eek, at least 2 w eeks, or at least one month that is within + / - 10% of an initial viscosity measured before the storage period. In yet other aspects, the precoat layer comprising the thermoplastic dispersion can exhibit a viscosity after a storage period of at least 3 days, of at least one week, at least 2 weeks, or at least one month that is within + / - 5% of an initial viscosity' measured before the storage period. It is understood that in some aspects, a storage period of this precoat layer can be determine by a possible microbial decomposition.

[0094] In certain aspects, the precoat layer is present in an amount of less than about 30 oz / sy, including exemplary values of less than about 20 oz / sy, about 15 oz / sy, less than about 10 oz / sy, less than about 8 oz / sy, less than about 6 oz / sy, less than about 4 oz / sy. In still other aspects, the precoat layer can be present in an amount of greater than about 4 oz / sy, greater than about 6 oz / sy, greater than about 8 oz / sy, greater than about 10 oz / sy, greater than about 15 oz / sy. greater than about 20 oz / sy or about 30 oz / sy.4. ADHESIVE LAYER

[0095] The carpet disclosed herein comprises an adhesive layer. The adhesive layer has a face side and an opposing back side. In aspects wherein the carpet comprises a precoat layer, the face side of the adhesive layer is attached to the opposing back side of the precoat layer. In other aspects, wherein the carpet does not comprise a precoat layer, the face side of the adhesive layer is attached to the opposing back side of the primary backing material. The adhesive layer comprises an adhesive composition comprising: i. a thermoplastic polyolefin, and ii. from about 0. 1 to about 75 % by weight of a particulate carbon-negative material.

[0096] The adhesive layer as described herein can be formed from the adhesive composition.

[0097] In some aspects, the particulate carbon-negative material is present in an amount of from about 0. 1 to about 75 % by weight of the adhesive composition. In a further aspect, the adhesive composition comprises from about 10 % to about 75 % by weight of a particulate carbon-negative material. The adhesive composition can comprise, for example, about 10 % to 65 %, 10 % to 50 %, 10 % to 40 %. 10 % to 30 %, 10 % to 20 %, 20 % to 75 %, 20 % to 60 %, 20 % to 50 %, 20 % to 40 %, 20 to 30 %, 30 % to 75 %, 30 % to 70 %, 30 % to 65 %, 30 % to 60 %, 30 % to 55 %, 30 % to 50 %, 30 % to 45 %, 30 % to 40 %, 40 % to75 %, 40 % to 70 %, 40 % to 65 %, 40 % to 60 %, 40 % to 55 %, 40 % to 50 %, 40 % to 45%, 45% to 75 %, 45 % to 70 %, 45 % to 65 %, 45 % to 60 %, 45 % to 55 %, 45 % to 50 %,50 % to 75 %, 50 % to 70 %, 50 % to 65 %. 50 % to 60 %, 50 % to 55 %, 55 % to 75 %. 55% to 70 %, 55 % to 65 %, 55 % to 60 %, 60 % to 75 %, 60 % to 70 %, 60 % to 65 %, 65 % to75 %, or about 65 % to 70 % by weight of a particulate carbon-negative material. The adhesive composition can comprise, for example, about 10 %, 15 %, 20 %, 25 %, 30 %, 35 %, 40 %. 45 %, 50 %, 55 %. 60 %, 65 %, 70 %. or about 75 % by weight of a particulate carbon-negative material.

[0098] In some aspects, the particulate carbon-negative material is present in an amount of from about 5 % to about 30 % by weight of the adhesive composition. The adhesive composition can comprise, for example, from about 5 % to 25 %, 5 % to 20 %, 5 % to 15 %, 5 % to 10 %, 10 % to 30 %, 10 % to 25 %, 10 % to 20 %, 10 % to 15 %, 15 % to 30 %, 15 % to 25 %, 15 % to 20 %, 20 % to 30 %, or about 25 % to 30 % by weight of a particulate carbon-negative material. The adhesive composition can comprise, for example, about 5 %, 10 %, 15 %, 20 %, 25 %, or about 30 % by weight of a particulate carbon-negative material.

[0099] In some aspects, the adhesive composition comprises from about 1.5 % to about 20 % by weight of a particulate carbon-negative material. The adhesive composition can comprise, for example, about 1 .5 % to 15%, 1 .5 % to 10 %, 1.5 % to 5 %, 1.5 % to 4.5 %, 1 .5 % to 4 %, 1.5 % to 3.5 %, 1.5 % to 3 %, 1.5 % to 2.5 %, 1.5 % to 2 %, 2 % to 20 %, 2 % to 15 %, 2 % to 10 %, 2 % to 5 %, 2 % to 4.5 %, 2 % to 4 %, 2 % to 3.5 %, 2 % to 3 %. 2 % to 2.5 %, 2.5 % to 20 %, 2.5 % to 15 %, 2.5 % to 10 %, 2.5 % to 5 %, 2.5 % to 4.5 %, 2.5 % to 4 %, 2.5 % to 3.5 %, 2.5 % to 3 %, 3 % to 20 %, 3 % to 15 %, 3 % to 10 %, 3 % to 5 %, 3 % to 4.5 %, 3 % to 4 %, 3 % to 3.5 %, 3.5 % to 20 %, 2.5 % to 15 %, 2.5 % to 10 %, 3.5 % to 5 %, 3.5 % to 4.5 %, 3.5 % to 4 %, 4 % to 20 %, 4 % to 15 %, 4 % to 10%, 4 % to 5 % , 4.5 % to 5 %, 10 % to 20 %, 15 % to 20 %, or about 15 % to 20 % by weight of a particulate carbon-negative material. The adhesive composition can comprise, for example, about 1.5 %, 2 %, 2.5 %, 3 %, 3.5 %, 4 %, 4.5 %, 5 %, 10 %, 15 %, or about 20 % by weight of a particulate carbon-negative material.

[0100] In certain aspects, exemplary and non-limiting particulate carbon-negative materials that can be present in the adhesive composition can include oolitic aragonite, a composite material comprising plastic matter and organic matter, or biochar.

[0101] In some aspects, the particulate carbon-negative material is a water-absorbing particulate carbon-negative material. Examples of water-absorbing particulate carbonnegative materials include, but are not limited to, oolitic aragonite, a composite material comprising plastic matter and organic matter, and biochar.

[0102] In some aspects, the adhesive composition comprises a particulate carbonnegative material being oolitic aragonite.

[0103] In some aspects, the oolitic aragonite is first screened to remove impurities such as shell fragments. In further aspects, the oolitic aragonite is subjected to grinding to yield smaller particles.

[0104] In aspects wherein oolitic aragonite is present in the adhesive composition, oolitic aragonite is present in an amount of from about 10 % to about 75 % by weight of the adhesive composition. The adhesive composition can comprise, for example, about 10 % to 60%, 10 % to 50 %, 10 % to 40 %, 10 % to 30 %, 10 % to 20 %, 20 % to 75 %, 20 % to 60 %, 20 % to 50 %, 20 % to 40 %, 30 % to 75 %, 30 % to 70 %, 30 % to 65 %, 30 % to 60 %, 30 % to 55 %, 30 % to 50 %, 30 % to 45 %. 30 % to 40 %, 40 % to 75 %, 40 % to 70 %. 40 % to 65 %, 40 % to 60 %, 40 % to 55 %, 40 % to 50 %, 40 % to 45 %, 45% to 75 %, 45 % to 70 %, 45 % to 65 %, 45 % to 60 %, 45 % to 55 %, 45 % to 50 %, 50 % to 75 %, 50 % to 70 %, 50 % to 65 %, 50 % to 60 %, 50 % to 55 %, 55 % to 75 %, 55 % to 70 %, 55 % to 65 %, 55 % to 60 %, 60 % to 75 %, 60 % to 70 %. 60 % to 65 %, 65 % to 75 %, or about 65 % to 70 % by weight of oolitic aragonite. The adhesive composition can comprise, for example, about 10 %, 15 %, 20 %, 25 %, 30 %, 35 %, 40 %, 45 %, 50 %, 55 %, 60 %, 65 %, 70 %, or about 75 % by weight of oolitic aragonite.

[0105] In some aspects, the adhesive composition comprises a particulate carbonnegative material being carbon-negative precipitated calcium carbonate.

[0106] In aspects wherein carbon-negative precipitated calcium carbonate is present in the adhesive composition, carbon-negative precipitated calcium carbonate is present in an amount of from about 10 % to about 75 % by weight of the adhesive composition. The adhesive composition can comprise, for example, about 10 % to 60 %, 10 % to 50 %, 10 % to 40 %, 10 % to 30 %, 10 % to 20 %, 20 % to 75 %, 20 % to 60 %, 20 % to 50 %, 20 % to 40%, 20 % to 30 %, 30 % to 75 %. 30 % to 70 %, 30 % to 65 %, 30 % to 60 %. 30 % to 55 %,30 % to 50 %, 30 % to 45 %, 30 % to 40 %, 40 % to 75 %, 40 % to 70 %, 40 % to 65 %, 40 % to 60 %, 40 % to 55 %, 40 % to 50 %, 40 % to 45 %, 45% to 75 %, 45 % to 70 %, 45 % to 65 %, 45 % to 60 %, 45 % to 55 %, 45 % to 50 %, 50 % to 75 %, 50 % to 70 %, 50 % to 65%, 50 % to 60 %, 50 % to 55 %. 55 % to 75 %, 55 % to 70 %, 55 % to 65 %. 55 % to 60 %,60 % to 75 %, 60 % to 70 %, 60 % to 65 %, 65 % to 75 %, or about 65 % to 70 % by weight of carbon-negative precipitated calcium carbonate. The adhesive composition can comprise, for example, about 10 %, 15 %, 20 %, 25 %, 30 %, 35 %, 40 %, 45 %, 50 %, 55 %, 60 %, 65 %, 70 %, or about 75 % by weight of carbon-negative precipitated calcium carbonate.

[0107] In certain aspects, the adhesive composition comprises a carbon negative material being a composite material comprising plastic matter and organic matter.

[0108] In some aspects, the composite material comprising plastic matter and organic matter is formed by mixing while heating the organic matter and plastic matter under shear forces.

[0109] In aspects wherein a composite material comprising plastic matter and organic matter is present in the adhesive composition, the composite material comprising plastic matter and organic matter is present in an amount of from about 1.5 % to 20 % by weight of the adhesive composition. The adhesive composition can comprise, for example, about 1.5 % to 15%, 1.5 % to 10 %, 1.5 % to 5 %, 1.5 % to 4.5 %, 1.5 % to 4 %, 1.5 % to 3.5 %, 1.5 % to 3 %, 1.5 % to 2.5 %, 1.5 % to 2 %, 2 % to 20 %, 2 % to 15 %, 2 % to 10 %, 2 % to 5 %, 2 % to 4.5 %. 2 % to 4 %, 2 % to 3.5 %, 2 % to 3 %. 2 % to 2.5 %, 2.5 % to 20 %, 2.5 % to 15 %,2.5 % to 10 %, 2.5 % to 5 %, 2.5 % to 4.5 %, 2.5 % to 4 %, 2.5 % to 3.5 %, 2.5 % to 3 %, 3 % to 20 %, 3 % to 15 %, 3 % to 10 %, 3 % to 5 %, 3 % to 4.5 %, 3 % to 4 %, 3 % to 3.5 %,3.5 % to 20 %, 2.5 % to 15 %, 2.5 % to 10 %, 3.5 % to 5 %, 3.5 % to 4.5 %, 3.5 % to 4 %, 4 % to 20 %. 4 % to 15 %. 4 % to 10%, 4 % to 5 % , 4.5 % to 5 %, 10 % to 20 %, 15 % to 20 %, or about 15 % to 20 % by weight of a composite material comprising plastic matter and organic matter. The adhesive composition can comprise, for example, about 1.5 %, 2 %, 2.5 %, 3 %, 3.5 %, 4 %, 4.5 %, 5 %, 10 %, 15 %, or about 20 % by weight of a composite material comprising plastic matter and organic matter.

[0110] In certain aspects, the adhesive composition comprises a particulate carbonnegative material being biochar.

[0111] In some aspects, the adhesive composition comprises a carbon-negative polymer resin. In some aspects, the adhesive composition comprises a carbon-negative polyethylene resin. In a further aspect, the carbon-negative polyethylene resin is not a water-absorbing carbon-negative material. In a yet further aspect, the carbon-negative polyethylene resin is not a water-absorbing particulate carbon negative material. An example of a carbon-negative polyethylene resin is commercially available.

[0112] The adhesive composition comprises a thermosplastic polyolefin. In some aspects wherein the adhesive composition comprises a thermoplastic polyolefin, the carpet does not comprise a precoat layer. In certain aspects, the adhesive composition comprising athermoplastic polyolefin comprises substantially linear ethylene polymers and homogeneously branched linear ethylene polymers (i.e., homogeneously branched ethylene polymers). Homogeneously branched ethylene polymers (including substantially linear ethylene polymers in particular) have low solidification 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).

[0113] In some aspects, when properly selected substantially linear ethylene polymers or homogeneously branched linear ethylene polymers are used in the adhesive composition, the low flexural modulus of these polymers offers advantages in ease of carpet installation and general carpet handling. Substantially linear ethylene polymers, in particular, when employed as an adhesive composition show enhanced mechanical adhesion to polypropylene which improves the consolidation and delamination resistance of the various carpet layers and components, i.e., polypropylene fibers, fiber bundles, the primary’ backing component. In some aspects, good abrasion resistance is especially important in commercial carpet cleaning operations as good abrasion resistance generally improves carpet durability.

[0114] In certain aspects, the adhesive composition comprising a substantially linear ethylene polymer or homogeneously branched linear ethylene polymer can provide a substantial fluid and particle barrier which enhances the hygienic properties of carpet.

[0115] In some further aspects, use of the adhesive composition comprising a substantially linear ethylene polymer or homogeneously branched linear ethylene polymer can allow' totally recyclable carpet products particularly where the carpet comprises polypropylene fibers.

[0116] The adhesive composition 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 used in the adhesive composition, is a substantially linear ethylene polymer characterized as having (a) a melt flow ratio, Iio / l2>5.63; (b) a molecular weight distribution, Mw / Mn. as determined by gel permeation chromatography and defined by the equation: (ATwATn)<( / io / I 2)~4.63; (c) a gas extrusion rheology such that the critical shear rate at onset of surface melt fracture for the substantially linear ethylene polymer is at least 50 percent greater than the critical shear rate at the onset ofsurface melt fracture for a linear ethylene polymer, wherein the linear ethylene polymer has a homogeneously branched short chain branching distribution and no long chain branching, and wherein the substantially linear ethylene polymer and the linear ethylene polymer are simultaneously ethylene homopolymers or interpolymers of ethylene and at least one C3- C20 a-olefm and have the same I2 and Mw / Mnand wherein the respective critical shear rates of the substantially linear ethylene polymer and the linear ethylene polymer are measured at the same melt temperature using a gas extrusion rheometer; and (d) a single differential scanning calorimetry. DSC, melting peak between -30° and 150° C.

[0117] In certain aspects, the molecular weight distribution (Mw / Mn) for the substantially linear ethylene polymers and homogeneous linear ethylene polymers used in the adhesive composition is generally from about 1.8 to about 2.8. Substantially linear ethylene polymers are known to have excellent processability, despite having a relatively narrow molecular weight distribution. Unlike homogeneously and heterogeneously branched linear ethylene polymers, the melt flow ratio (I10 / I2) of substantially linear ethylene polymers can be varied essentially independently of their molecular weight distribution, Mw / Mn.

[0118] In some aspects, the adhesive composition comprising homogeneously branched ethylene polymers includes interpolymers of ethylene and at least one a-olefm prepared by a solution, gas phase, or slurry polymerization process, or combinations thereof. In some aspects the a-olefins are represented by the following formula:

[0119] CH2=CHR

[0120] where R is a hydrocarbyl radical. Further, R may be a hydro-carbyl radical having from one to twenty carbon atoms and as such the formula includes C3-C20 a-olefms. In other aspects, a-olefins for use as comonomers include propylene, 1 -butene, 1 -isobutylene, 1- pentene, 1-hexene, 4-methyl-l-pentene, 1-heptene and 1-octene, as well as other comonomer types such as styrene, halo- or alkyl-substituted styrenes, tetrafluoro-ethylene, vinyl benzocyclobutene, 1 ,4-hexadiene, 1,7-octadiene, and cycloalkenes, e g., 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 secondary' backing materials comprised of higher a-olefms will have especially improved toughness. In yet other aspects, the comonomer will be 1-octene and the ethylene polymer will be prepared in a solution process.

[0121] In certain aspects, the density of the substantially linear ethylene polymer or homogeneously branched linear ethylene polymer, as measured in accordance with ASTM D- 792, does not exceed about 0.92 g / cc, and is generally in the range from about 0.85 g / cc to about 0.92 g / cc, from about 0.86 g / cc to about 0.91 g / cc, and from about 0.86 g / cc to about 0.90 g / cc.

[0122] In yet further aspects, the molecular weight of the homogeneously branched linear ethylene polymer or substantially linear ethylene polymer can be characterized using a melt index measurement according to ASTM D-1238, Condition 190° C / 2. 16 kg (formerly known as “Condition (E)” and also known as I2). Melt index is inversely proportional to the molecular weight of the polymer. Thus, the higher the molecular weight, the low er the melt index, although the relationship is not linear. The melt index for the homogeneously branched linear ethylene polymer or substantially linear ethylene polymer is generally from about 1 grams / 10 minutes (g / 10 min) to about 500 g / 10 min, about 2 g / 10 min to about 300 g / 10 min, from about 5 g / 10 min to about 100 g / 10 min, from about 10 g / 10 min to about 50 g / 10 min, and about 25 to about 35 g / 10 min.

[0123] In some other aspects, an additional measurement can be useful in characterizing the molecular weight of the homogeneous linear ethylene polymer or the substantially linear ethylene polymer and can be performed using a melt index measurement according to ASTM D-1238, Condition 190° C / 10 kg (formerly known as “Condition (N)” and also known as I10). The ratio of the ho and the hmelt index terms is the melt flow ratio and is designated as I10 / I2. For the substantially linear ethylene polymer, the I10 / I2 ratio indicates the degree of long chain branching, i.e., the higher the I10 / I2 ratio, the more long chain branching in the polymer. The I10 / I2 ratio of the substantially linear ethylene polymer is at least about 6.5, at least about 7, or at least about 8. The I10 / I2 ratio of the homogeneously branched linear ethylene polymer is generally less than about 6.3.

[0124] In some aspects, the ethylene polymers can have a relative low modulus. That is, the ethylene polymer is characterized as having a 2% secant modulus 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 in accordance with ASTM D790.

[0125] In certain aspects, the ethylene polymers described herein are substantially amorphous or totally amorphous. That is, the ethylene polymer is characterized as having a percent crystallinity less than about 40 percent, less than about 30 percent, more less thanabout 20. and less than about 10 percent, as measured by differential scanning calorimetry using the equation:

[0126] percent crystallinity % = (Hf / 292)xl00, where Hfis the heat of fusion in Joules / gram.

[0127] In other aspects, the homogeneously branched ethylene polymer (HBEP) can be used alone or can be blended or mixed with one or more synthetic or natural polymeric material. In some aspects, the polymers for blending or mixing with homogeneously branched ethylene polymers used, but are not limited to, another homogeneously branched ethylene polymer, low density polyethylene, heterogeneously branched LLDPE, heterogeneously branched ULDPE, medium density polyethylene, high density polyethylene, grafted polyethylene (e.g. a maleic anhydride extrusion grafted heterogeneously branched linear low polyethylene or a maleic anhydride extrusion grafted homogeneously branched ultra low density polyethylene), ethylene acrylic acid copolymer, ethylene vinyl acetate copolymer, ethylene ethyl acrylate copolymer, polystyrene, polypropylene, polyester, polyurethane, polybutylene, polyamide, polycarbonate, rubbers, ethylene propylene polymers, ethylene styrene polymers, styrene block copolymers, and vulcanates.

[0128] In further aspects, the adhesive composition can comprise a blend of at least two polyethylenes, wherein the polyethylene can comprise a homogeneously branched ethylene polymer (HBEP) or a substantially linear ethy lene polymer (SLEP), or mixtures thereof. In other aspects, the adhesive layer can comprise a blend of at least three or four, or more polyethylenes, wherein the polyethylenes comprise a homogeneously branched ethylene polymer (HBEP) or a substantially linear ethylene polymer (SLEP), or mixtures thereof. Still further, the adhesive composition can comprise a polyethylene comprising at least about 80% by weight of at least one (or two or more) HBEP or SLEP as measured by weight of the polyethylene, including exemplary values of about 85, 90, 95, 97, 98. or about 99% by weight of the polyethylene, where any value can comprise an upper or a lower endpoint, as appropriate.

[0129] In the aspects, where the blend of at least two (or three or more) polyethylenes is used, the amount of each polyethylene can be individually varied in the amounts of, for example, from 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 the individual components, and any value can be used as an upper or a lower endpoint, as appropriate.

[0130] The density of the polyethylene components in the blend can be from about 0.860, 0.870, 0.880, 0.885, 0.890, 0.895, 0.900, 0.905, or about 0.910 g / cc, where any value can comprise an upper or a lower endpoint, as appropriate.

[0131] The actual blending or mixing of various polymers may 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 a Banbury mixer and multiple reactor polymerization. In some aspects, the blends or mixtures include a homogeneously branched ethylene polymer and a heterogeneously branched ethylene a- olefin interpolymer, wherein the a-olefm is a C3-C8 a-olefm prepared using two reactors operated in parallel or in series with different catalyst systems employed in each reactor. Multiple reactor polymerizations are described in copending applications U.S. Ser. No. 08 / 544,497, filed Oct. 18, 1995 and U.S. Ser. No. 08 / 327,156, filed Oct. 21, 1994, the disclosures of all three of which are incorporated herein by reference. In some aspects, multiple reactor polymerizations comprise non-adiabatic solution loop reactors as described in provisional applications U.S. Ser. No. 60 / 014,696 and U.S. Ser. No. 60 / 014.705, both filed Apr. 1, 1996, the disclosures of all of which are incorporated herein by reference.

[0132] In another aspect, the adhesive composition can comprise a modified homogeneously branched ethylene polymer. In particular, in certain aspects, the at least one homogeneously branched ethylene polymer that can be present within the adhesive layer can be modified by the addition of at least one adhesive polymeric additive. Suitable adhesive polymeric additives include, for example and without limitation, polymer products comprised of (1) one or more ethylenically unsaturated carboxylic acids, anhydrides, alkyd esters and half esters, e.g., acry lic acid, methacry lic acid, maleic acid, maleic anhydride, itaconic acid, fumaric acid, crotonic acid and citraconic acid, citraconic anhydride, succinnic acid, succinnic anhydride, methyl hydrogen maleate, and ethyl hydrogen maleate; esters of ethylenically unsaturated carboxylic acids, e.g., ethyl acrylate, methyl methacrylate, ethyl methacry late, methyl acrylate, isobuty l acry late, and methy l fumarate; unsaturated esters of carboxy lic acids, e g., vinyl acetate, vinyl propionate, and vinyl benzoate; and ethylenically unsaturated amides and nitriles e.g., acrylamide, acrylonitrile, methacrylonitrile and fumaronitrile; and (2) one or more ethylenically unsaturated hydrocarbon monomers such as aliphatic a-olefm monomers, e.g., ethylene, propylene, butene-1 and isobutene; conjugated dienes, e.g., butadiene and isoprene; and monovinylidene aromatic carbocyclic monomers, e.g., styrene, a-methylstyrene. toluene, and t-butylstyrene.

[0133] A modified homogeneously branched ethylene polymer for use in the adhesive composition can be conveniently prepared by known techniques such as, for example, by interpolymerization or by a polymerization procedure followed by a chemical or extrusion grafting procedure. Suitable grafting techniques are described in U.S. Pat. Nos. 4,762,890; 4,927,888; 4.230,830; 3,873,643; and 3,882,194, the disclosures of all of which are incorporated herein by reference.

[0134] In some aspects, the adhesive polymeric additives for use in the adhesive composition can include maleic anhydride grafts wherein maleic anhydride is grafted onto an ethylene polymer at a concentration of about 0. 1 to about 5.0 weight percent, about 0.5 to about 1.5 weight percent. The presence of ethylene polymer / maleic anhy dride grafts as adhesive polymenc additives in the adhesive composition can improve the performance and operating window of extrusion coated homogeneously branched ethylene polymers, especially when used in connection with polar polymers such as for example, but is not limited to, nylon and polyester faced carpets. The improvement pertained to substantially higher comparative abrasion resistance and tuft bind strength. In an exemplary aspect, a composition for forming a maleic anhydride graft is the Amplify® GR 204 available from Dow Chemicals.

[0135] In further aspects, the ethylene polymers for use as the grafted host polymer include low densify polyethylene (LDPE), high densify polyethylene (HDPE), heterogeneously branched linear low densify polyethylene (LLDPE), homogeneously branched linear ethylene polymers and substantially linear ethylene polymers. In some aspects, the host ethylene polymers have a polymer densify 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 yet other aspects, the substantially linear ethylene polymers and high densify polyethylene are utilized as host ethylene polymers.

[0136] In some aspects, the adhesive layer is an extruded adhesive layer. In some aspects, it is contemplated that the adhesive layer can be extruded or applied by any other technique known in the art. In some aspects, the adhesive composition may optionally include exemplary additives such as foaming agents, pEI controllers, flame retardants, fillers, tackifiers, wetting agents, dispersing agents, anti-microbial agents, lubricants, dyes, antioxidants, and the like, which are well known to those skilled in the art, without loss of the characteristic properties.

[0137] In one aspect, the adhesive composition can further comprise one or more flame retardants sufficient to ensure the carpet structure satisfies the requirements of the radiant flux floor covering test according to the ASTM-E648 testing procedures. In particular, according to certain aspects, the carpets exhibit a Class 1 critical radiant flux of greater than 0.45 watts per cm2as measured according to ASTM-E648. According to other aspects, the carpets described herein can exhibit a Class 2 critical radiant flux in the range of from 0.22 to 0.44 watts per cm2as measured according to ASTM-E648. In still further aspects, the carpets can exhibit an unclassifiable critical radiant flux of less than 0.22 watts per cm2as measured according to ASTM-E648.

[0138] Exemplary flame retardants that can be incorporated into the adhesive composition include, without limitation, organo-phosphorous 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, silicon dioxide, calcium carbonate, resourcinol bis-(diphenyl phosphate), brominated latex base, antimony trioxide, strontium borate, strontium phosphate, monomeric N-alkoxy hindered amine (NOR HAS), triazine and its derivatives, high aspect ratio talc, phosphated esters, organically modified nanoclays and nanotubes, non-organically modified nanoclays and nanotubes, ammonium polyphosphate, polyphosphoric acid, ammonium salt, triaryl phosphates, isopropylated triphenyl phosphate, phosphate esters, magnesium hydroxide, zinc borate, bentonite (alkaline activated nanoclay and nanotubes), organoclays, aluminum trihydrate (ATH), azodicarbonamide, diazenedicarboxamide, azodicarbonic acid diamide (ADC), triaryl phosphates, isopropylated triphenyl phosphate, triazine derivatives, alkaline activated organoclay and aluminum oxide. Any desired amount of flame retardant can be used in the adhesive composition and the selection of such amount will depend, in part, upon the particular flame retardant used and desired carpet applications. Such amounts can be readily determined through no more than routine experimentation.

[0139] Exemplary and non-limiting additional fillers that can be incorporated into the adhesive composition can include calcium carbonate in a form different than oolitic aragonite, carbon-negative precipitated calcium carbonate, fly-ash, recycled calcium carbonate in a form different than oolitic aragonite, aluminum trihydrate, talc, nano-clay, barium sulfate, barite, barite glass fiber, glass powder, glass cullet, metal powder, alumina, hydrated alumina, clay, magnesium carbonate, calcium sulfate, silica, glass, fumed silica, carbon black, graphite, cement dust, feldspar, nepheline, magnesium oxide, zinc oxide.aluminum silicate, calcium silicate, titanium dioxide, titanates, glass microspheres, chalk, calcium oxide, and any combination thereof. In one aspect, the secondary backing material comprises inorganic filler with high heat content. In some aspects, it is for the filler to exhibit relatively high heat content. Examples of such fillers include, but are not limited to, calcium carbonate in a form different than oolitic aragonite, carbon-negative precipitated calcium carbonate, aluminum trihydrate, talc, and barite. The exemplified high heat content fillers allow the extrudate to remain at elevated temperatures longer with the beneficial result of providing enhanced encapsulation and penetration. In this aspect, the high heat content fillers should be ground or precipitated to a size that can be conveniently incorporated in an extrusion coating melt stream. Exemplary non-limiting particle sizes for the inorganic filler material can include particle sizes in the range of from about 1 to about 50 microns. Still further, it should also be understood that the filler component can be present in any desired amount. However, in an exemplary aspect, the filler is present in an amount in the range of from about 10 weight % to about 90 weight %, based upon the total weight of the adhesive composition, including exemplary amounts of about 15 weight %, 20 weight %, 25 weight %, 30 weight %, 35 weight %, 40 weight %, 45 weight %, 50 weight %, 55 weight %, 60 weight %, 65 weight %, 70 weight %, 75 weight %, 80 weight %, and about 85 weight %. Still further, the amount of filler present can be in any range derived from any two of the above stated weight percentages.

[0140] In still another aspect, the adhesive composition can further comprise one or more tackifying additives. The tackifier can for example be tall oil or rosin based or, alternatively, can be an aliphatic or aliphatic aromatic hydrocarbon blend resin. As the tackifier is an optional component, the amount of tackifier can be, when present, in the range of from greater than 0 weight percent up to and even exceeding about 50 weight % of the adhesive composition. For example, in one aspect, the amount of tackifier can be in the range of from about 5 weight % to about 45 weight %. In still another aspect, the amount of tackifier can be in the range of from about 10 weight % to about 20 weight %.5. REINFORCING LAYER

[0141] The carpet disclosed herein comprises a reinforcing layer. The reinforcing layer has a face side and an opposing back side. The face side of the reinforcing layer is attached to the opposing back side of the adhesive layer.

[0142] In some aspects, the reinforcing layer is embedded between the adhesive layer and the secondary backing material. The reinforcing layer enhances the dimensional stabilityof the carpet. Although the adhesive layer and the secondary backing layer can grow or shrink due to, for example, water absorption, the reinforcing layer can further mitigate curling of the carpet tile by reducing lateral growth and shrink. The carpets as disclosed herein comprise an adhesive layer comprising a water-absorbing particulate carbon-negative material. Thus, when the adhesive layer absorbs water and has increased growth relative to the secondary backing material, the carpet tile will tend to “dome"’ (i.e. , center of a face-up tile will rise slightly off the floor relative to the comers) rather than curl.

[0143] Suitable reinforcing layers include dimensionally and thermally stable fabrics such as mesh scrims, non-woven or wet-laid fiberglass scrims, as well as woven and nonwoven thermoplastic fabrics (e.g. polypropylene, nylon and polyester). In some aspects, the reinforcement layer is a fiberglass scrim, for example, Evalith™ that is commercially available from Johns Manville (about 2.0 oz / square yard). Alternatively, in other aspects, a reinforcement layer is a fiberglass scrim sold by Owens Coming (about 2.0 oz / square yard).

[0144] In some aspects, the reinforcing layer comprises a combination of fiberglass and thermoplastic fibers. Such a reinforcing layer is commercially available from Freudenberg Performance Materials under the tradename Colback®. In such aspects, such a reinforcing layer may prevent moisture from reaching the adhesive layer to a degree such that the dimensional stability' of the carpet is not adversely impacted. In certain aspects, the carpet does not include a secondary backing material when the reinforcing layer comprises a combination of fiberglass and thermoplastic fibers.6. OPTIONAL SECONDARY BACKING MATERIAL

[0145] The carpet disclosed herein optionally comprises a secondary backing material. The secondary' backing material has a face side and an opposing back side. When present, the face side of the secondary backing material is attached to the opposing back side of the reinforcing layer. The secondary backing material comprises a thermoplastic polyolefin.

[0146] The secondary backing material provides dimensional stability to the carpet. In some aspects, the opposing back side of the secondary' backing material contacts the ground on which the carpet is laid upon. In some aspects wherein the reinforcing layer comprises a combination of fiberglass and thermoplastic fibers, the carpet does not comprise a secondary backing material.

[0147] In certain aspects, the secondary backing material does not comprise a particulate carbon-negative material. In some aspects, the secondary backing material comprises aparticulate carbon-negative material. In further aspects, the secondary’ backing material comprises a particulate carbon-negative material being a water-absorbing particulate carbonnegative material.

[0148] In some aspects, the secondary backing material comprises a water-absorbing particulate carbon-negative material in a weight % that is less than a weight % of a waterabsorbing particulate carbon-negative material in the adhesive layer. In aspects wherein the secondary backing material comprises a water-absorbing particulate carbon-negative material, it is essential for the purposes of carpet curl mitigation that the weight % of waterabsorbing particulate carbon-negative material not exceed a w eight %of water-absorbing particulate carbon-negative material in the adhesive layer. This is because it is desired that when the carpet absorbs water, the adhesive layer, which comprises a higher weight % of water-absorbing particulate carbon-negative material, will absorb more w ater and experience higher grow th relative to the secondary backing material. Such growth yields a carpet with a “dome"’ (i.e., the center of a face-up tile will rise slightly off the floor relative to the comers) rather than curl (i.e., comers of a face-up tile will rise slightly off the floor relative to the center). In some aspects, the secondary backing material comprises a w ater-absorbing particulate carbon-negative material in a weight % that is about 10 %, 20 %, 30 %, 40 %, 50 %, 60 %, 70 %, 80 %, 90 %, 95 %, 97 %, 99 %, or 99.5 % less than the w eight % of a waterabsorbing particulate carbon-negative material in the adhesive layer.

[0149] In some aspects, the water-absorbing particulate carbon-negative material in the secondary backing material and the adhesive layer are identical. In other aspects, the waterabsorbing particulate carbon-negative material in the secondary' backing material and the adhesive layer are different. In further aspects, the secondary backing material comprises more than one water-absorbing particulate carbon-negative material. In such aspects wherein the secondary backing material comprises more than one water-absorbing particulate carbonnegative material, the weight % of the w ater-absorbing particulate carbon-negative materials in the secondary' backing material is less than the total w eight of water-absorbing particulate carbon-negative materials in the adhesive layer.

[0150] In some aspects, the secondary backing material comprises a water-absorbing particulate carbon-negative material in a weight percent that is less than the weight percent of a water-absorbing particulate carbon-negative material in the adhesive layer. In some aspects, the secondary' backing material comprises a water-absorbing particulate carbon-negative material in a weight percent that is about 10 %, 20 %, 30 %, 40 %, 50 %, 60 %, 70 %, 80 %,90 %, 95 %, 97 %, 99 %, or 99.5 % less than the weight percent of a water-absorbing particulate carbon-negative material in the adhesive layer.

[0151] In such aspects wherein the secondary backing material comprises more than one water-absorbing particulate carbon-negative material, the weight percent of the waterabsorbing particulate carbon-negative materials in the secondary7backing material is less than the total weight percent of water-absorbing particulate carbon-negative materials in the adhesive layer.

[0152] In some aspects, the secondary backing material comprises a water-absorbing particulate carbon-negative material, wherein the weight percent of the water-absorbing particulate carbon-negative material in the secondary backing material relative to the weight percent of the water-absorbing particulate carbon-negative material in the adhesive layer is at a ratio of from about 1 :2 to 1 : 1000. The weight percent of the water-absorbing particulate carbon-negative material in the secondary backing relative to the weight percent of the waterabsorbing particulate carbon-negative material in the adhesive layer can be, for example, from about 1:2 to 1 :900, 1:2 to 1:500, 1:2 to 1:300, 1 :2 to 1 : 100, 1:2 to 1:75, 1:2 to 1:50, 1:2 to 1 :25, 1:2 to 1 : 10, l : 10 to 1 : 1000, 1: 10 to 1 :900. l: 10 to 1:500, 1: 10 to 1 :300, l : 10 to 1: 10 to 1 : 100, 1 :10 to 1 :50, 1: 10 to 1 :25, 1 :25 to 1 : 1000, 1 :25 to 1 :900, 1 :25 to 1 :700, 1 :25 to 1:500, 1:25 to 1:300, 1:25 to 1: 100, 1:25 to 1:50, 1:50 to 1: 1000, 1 :50 to 1:900, 1 :50 to 1 :500, 1:50 to 1:300, 1:50 to 1: 100, 1: 100 to 1 : 1000, 1: 100 to 1:900, 1: 100 to 1 :500, or about 1 :500 to 1 : 1000.

[0153] In some aspects, wherein the secondary backing material and the adhesive layer both comprise a water-absorbing particulate carbon-negative material, the weight percent of the water-absorbing particulate carbon-negative material in the adhesive layer relative to the weight percent of the water-absorbing particulate carbon-negative material in the secondary backing material is at least 2, 3, 4. 5, 10. or at least 20 times higher.

[0154] In some aspects, the secondary backing material comprises a non-water absorbing carbon negative material and the adhesive layer comprises a water-absorbing particulate carbon-negative material.

[0155] In certain aspects wherein the adhesive composition in the adhesive layer comprises from about 10 % to about 75 % by weight of a water-absorbing particulate carbonnegative material, the secondary backing material can comprise, for example, about 10 % to 70 %, 10 % to 60 %, 10 % to 50 %, 10 % to 40 %, 10 % to 30 %, 10 % to 20 %, 20 % to 75%, 27 % to 68 %, 24 % to 60 %, 21 % to 52 %, 18 % to 45 %, 15 % to 38 %, 12 % to 30 %, 9 % to 23 %, 6 % to 15 %, 3 % to 7.5 %, 1.5 % to 3.8 %, 1 % to 2.5 %, 0.5 % to 1 %, or about 0.1 % to 0.4 % by weight of a water-absorbing particulate carbon-negative material.

[0156] In certain aspects wherein the adhesive composition in the adhesive layer comprises from about 1.5 % to about 20 % by weight of a water-absorbing particulate carbon-negative material, the secondary backing material can comprise, for example, about 1.4 % to 15 %, 1.4 % to 10 %, 1.4 % to 10 %, 1.4 % to 4.5 %, 1.2 % to 4 %, 1.1 % to 3.5 %, 0.9 % to 3 %, 0.75 % to 2.5 %, 0.6 % to 2 %, 0.45 % to 1.5 %, 0.3 % to 1% , 0.15 % to 0.5 %, 0.05 % to 0.15 %, 0.015 % to 0.05 %, or about 0.0075 % to 0.025 % by weight of a waterabsorbing particulate carbon-negative material.

[0157] In some aspects, the particulate carbon-negative material is oolitic aragonite, carbon-negative precipitated calcium carbonate, biochar, or a composite material comprising plastic matter and organic matter.

[0158] In some aspects, the secondary backing material comprises a carbon-negative polymer resin. In some aspects, the secondary backing material comprises a carbon-negative polyethylene resin. In a further aspect, the carbon-negative polyethylene resin is not a waterabsorbing carbon-negative material. In a yet further aspect, the carbon-negative polyethylene resin is not a water-absorbing particulate carbon-negative material. An example of a carbonnegative polyethylene resin is commercially available from Braskem. under the tradename I’m green™.

[0159] In certain aspects, the secondary backing material comprising a thermoplastic polyolefin comprises substantially linear ethylene polymers and homogeneously branched linear ethylene polymers (i.e., homogeneously branched ethylene polymers).Homogeneously branched ethylene polymers (including substantially linear ethylene polymers in particular) have low solidification 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).

[0160] In some aspects, when properly selected substantially linear ethylene polymers or homogeneously branched linear ethylene polymers are used as the secondary backing materials, the low flexural modulus of these polymers offers advantages in ease of carpetinstallation and general carpet handling. Substantially linear ethylene polymers, in particular, when employed as a secondary backing material show enhanced mechanical adhesion to polypropylene which improves the consolidation and delamination resistance of the various carpet layers and components, i.e., polypropylene fibers, fiber bundles, the primary backing component. In some aspects, good abrasion resistance is especially important in commercial carpet cleaning operations as good abrasion resistance generally improves carpet durability.

[0161] In certain aspects, the secondary backing material comprising a substantially linear ethylene polymer or homogeneously branched linear ethylene polymer can provide a substantial fluid and particle barrier which enhances the hygienic properties of carpet.

[0162] In some further aspects, use of the secondary backing material comprising a substantially linear ethylene polymer or homogeneously branched linear ethylene polymer can allow totally recyclable carpet products particularly where the carpet comprises polypropylene fibers.

[0163] 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 used in the secondary backing material, is a substantially linear ethylene polymer characterized as having (a) a melt flow ratio, Iio / l2>5.63; (b) a molecular weight distribution, Mw / Mn, as determined by gel permeation chromatography and defined by the equation: (A / w.io / I 2)_4.63; (c) a gas extrusion rheology such that the critical shear rate at onset of surface melt fracture for the substantially linear ethylene polymer is at least 50 percent greater than the critical shear rate at the onset of surface melt fracture for a linear ethylene polymer, wherein the linear ethylene polymer has a homogeneously branched short chain branching distribution and no long chain branching, and wherein the substantially linear ethylene polymer and the linear ethylene polymer are simultaneously ethylene homopolymers or interpolymers of ethylene and at least one C3-C20 a-olefin and have the same I2 and Mw / Mnand wherein the respective critical shear rates of the substantially linear ethylene polymer and the linear ethylene polymer are measured at the same melt temperature using a gas extrusion rheometer; and (d) a single differential scanning calorimetry, DSC, melting peak between -30° and 150° C.

[0164] In certain aspects, the molecular weight distribution (Mw / Mn) for the substantially linear ethylene polymers and homogeneous linear ethylene polymers used in the secondary' backing material is generally from about 1.8 to about 2.8. Substantially linear ethylenepolymers are known to have excellent processability, despite having a relatively narrow molecular weight distribution. Unlike homogeneously and heterogeneously branched linear ethylene polymers, the melt flow ratio (I10 / I2) of substantially linear ethylene polymers can be varied essentially independently of their molecular weight distribution, Mw / Mn.

[0165] In some aspects, the secondary' backing material comprising homogeneously- branched ethylene polymers includes interpolymers of ethylene and at least one a-olefin prepared by a solution, gas phase, or slurry polymerization process, or combinations thereof. In some aspects the a-olefins are represented by the following formula:

[0166] CH2=CHR

[0167] where R is a hydrocarbyl radical. Further, R may be a hydro-carbyl radical having from one to twenty carbon atoms and as such the formula includes C3-C20 a-olefins. In other aspects, a-olefins for use as comonomers include propylene, 1 -butene, 1 -isobutylene, 1- pentene, 1 -hexene, 4-methyl-I -pentene, 1 -heptene and 1 -octene, as well as other comonomer types such as styrene, halo- or alkyl-substituted styrenes, tetrafluoro-ethylene, vinyl benzocyclobutene, 1 ,4-hexadiene, 1.7-octadiene, and cycloalkenes, e g., 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 secondary backing materials comprised of higher a-olefins will have especially improved toughness. In yet other aspects, the comonomer will be 1 -octene and the ethylene polymer will be prepared in a solution process.

[0168] In certain aspects, the density of the substantially linear ethylene polymer or homogeneously branched linear ethylene polymer, as measured in accordance with ASTM D- 792, does not exceed about 0.92 g / cc, and is generally in the range from about 0.85 g / cc to about 0.92 g / cc, from about 0.86 g / cc to about 0.91 g / cc, and from about 0.86 g / cc to about 0.90 g / cc.

[0169] In yet further aspects, the molecular weight of the homogeneously branched linear ethylene polymer or substantially linear ethylene polymer can be characterized using a melt index measurement according to ASTM D-1238, Condition 190° C / 2.16 kg (formerly known as "Condition (E)” and also known 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 the relationship is not linear. The melt index for the homogeneously branched linear ethylene polymer or substantially linear ethylene polymer is generally fromabout 1 grams / 10 minutes (g / 10 min) to about 500 g / 10 min, about 2 g / 10 min to about 300 g / 10 min, from about 5 g / 10 min to about 100 g / 10 min, from about 10 g / 10 min to about 50 g / 10 min, and about 25 to about 35 g / 10 min.

[0170] In some other aspects, an additional measurement can be useful in characterizing the molecular weight of the homogeneous linear ethylene polymer or the substantially linear ethylene polymer and can be performed using a melt index measurement according to ASTM D-1238, Condition 190° C / 10 kg (formerly known as '‘Condition (N)” and also known as Iio). The ratio of the ho and the Emelt index terms is the melt flow ratio and is designated as I10 / I2. For the substantially linear ethylene polymer, the I10 / I2 ratio indicates the degree of long chain branching, i.e., the higher the I10 / I2 ratio, the more long chain branching in the polymer. The I10 / I2 ratio of the substantially linear ethylene polymer is at least about 6.5, at least about 7. or at least about 8. The I10 / I2 ratio of the homogeneously branched linear ethylene polymer is generally less than about 6.3.

[0171] In some aspects, the ethylene polymers can have a relative low modulus. That is, the ethylene polymer is characterized as having a 2% secant modulus 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 in accordance with ASTM D790.

[0172] In certain aspects, the ethylene polymers described herein are substantially amorphous or totally amorphous. That is, the ethylene polymer is characterized as having a percent crystallinity less than about 40 percent, less than about 30 percent, more less than about 20. and less than about 10 percent, as measured by differential scanning calorimetry using the equation:

[0173] percent crystallinity % = (Hf / 292)xl00, where Hfis the heat of fusion in Joules / gram.

[0174] In other aspects, the homogeneously branched ethylene polymer (HBEP) can be used alone or can be blended or mixed with one or more synthetic or natural polymeric material. In some aspects, the polymers for blending or mixing with homogeneously branched ethylene polymers used in the secondary backing material include, but are not limited to, another homogeneously branched ethylene polymer, low density polyethylene, heterogeneously branched LLDPE, heterogeneously branched ULDPE. medium density polyethylene, high density polyethylene, grafted polyethylene (e.g. a maleic anhydride extrusion grafted heterogeneously branched linear low polyethylene or a maleic anhydrideextrusion grafted homogeneously branched ultra low density polyethylene), ethylene acrylic acid copolymer, ethylene vinyl acetate copolymer, ethylene ethyl acrylate copolymer, polystyrene, polypropylene, polyester, polyurethane, polybutylene, polyamide, polycarbonate, rubbers, ethylene propylene polymers, ethylene styrene polymers, styrene block copolymers, and vulcanates.

[0175] In further aspects, the secondary backing material can comprise a blend of at least two polyethylenes, wherein the polyethylene can comprise a homogeneously branched ethylene polymer (HBEP) or a substantially linear ethylene polymer (SLEP), or mixtures thereof. In other aspects, the secondary7backing material can comprise a blend of at least three or four, or more polyethylenes, wherein the poly ethylenes 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% by weight of at least one (or two or more) HBEP or SLEP as measured by weight of the polyethylene, including exemplary values of about 85, 90, 95, 97, 98, or about 99% by weight of the polyethylene, where any value can comprise an upper or a lower endpoint, as appropriate.

[0176] In the aspects, where the blend of at least two (or three or more) polyethylenes is used, the amount of each polyethylene can be individually varied in the amounts of, for example, from 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 the individual components, and any value can be used as an upper or a lower endpoint, as appropriate.

[0177] The density of the polyethylene components in the blend can be from about 0.860, 0.870, 0.880, 0.885, 0.890, 0.895, 0.900, 0.905, or about 0.910 g / cc, where any value can comprise an upper or a lower endpoint, as appropriate.

[0178] The actual blending or mixing of various polymers may 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 a Banbury mixer and multiple reactor polymerization. In some aspects, the blends or mixtures include a homogeneously branched ethylene polymer and a heterogeneously branched ethylene a- olefin interpolymer, wherein the a-olefin is a C?-Cs a-olefin prepared using two reactors operated in parallel or in series with different catalyst systems employed in each reactor. Multiple reactor polymerizations are described in copending applications U.S. Ser. No. 08 / 544.497, filed Oct. 18, 1995 and U.S. Ser. No. 08 / 327,156, filed Oct. 21, 1994, thedisclosures of all three of which are incorporated herein by reference. In some aspects, multiple reactor polymerizations comprise non-adiabatic solution loop reactors as described in provisional applications U.S. Ser. No. 60 / 014,696 and U.S. Ser. No. 60 / 014,705, both filed Apr. 1, 1996, the disclosures of all of which are incorporated herein by reference.

[0179] In another aspect, the secondary backing material can comprise a modified homogeneously branched ethylene polymer. In particular, in certain aspects, the at least one homogeneously branched ethylene polymer that can be present within the secondary backing material can be modified by the addition of at least one adhesive polymeric additive. Suitable adhesive polymeric additives include, for example and without limitation, polymer products comprised of (1) one or more ethylenically unsaturated carboxylic acids, anhydrides, alkyl esters and half esters, e.g., acrylic acid, methacrylic acid, maleic acid, maleic anhydride, itaconic acid, fumaric acid, crotonic acid and citraconic acid, citraconic anhydride, succinnic acid, succinnic anhydride, methyl hydrogen maleate, and ethyl hydrogen maleate; esters of ethylenically unsaturated carboxylic acids, e.g., ethyl acrylate, methyl methacrylate, ethyl methacrylate, methyl acrylate, isobutyl acrylate, and methyl fumarate; unsaturated esters of carboxylic acids, e.g., vinyl acetate, vinyl propionate, and vinyl benzoate; and ethylenically unsaturated amides and nitriles e.g., acrylamide, acrylonitrile, methacrylonitrile and fumaronitrile; and (2) one or more ethylenically unsaturated hydrocarbon monomers such as aliphatic a-olefm monomers, e.g., ethylene, propylene, butene-1 and isobutene; conjugated dienes, e.g., butadiene and isoprene; and monovinylidene aromatic carbocyclic monomers, e.g., styrene, a-methylstyrene, toluene, and t-butylstyrene.

[0180] A modified homogeneously branched ethylene polymer for use in the secondary backing materials can be conveniently prepared by known techniques such as, for example, by interpolymerization or by a polymerization procedure followed by a chemical or extrusion grafting procedure. Suitable grafting techniques are described in U.S. Pat. Nos. 4,762,890; 4,927,888; 4,230,830; 3,873,643; and 3,882,194, the disclosures of all of which are incorporated herein by reference.

[0181] In some aspects, the adhesive polymeric additives for use in the secondary backing material can include maleic anhydride grafts wherein maleic anhydride is grafted onto an ethylene polymer at a concentration of about 0. 1 to about 5.0 weight percent, about 0.5 to about 1.5 weight percent. The presence of ethylene polymer / maleic anhydride grafts as adhesive polymeric additives can improve the performance and operating window of extrusion coated homogeneously branched ethylene polymers as the secondary backingmaterial, especially when used in connection with polar polymers such as for example, but is not limited to, nylon and polyester faced carpets. The improvement pertained to substantially higher comparative abrasion resistance and tuft bind strength. In an exemplar}7aspect, a composition for forming a maleic anhydride graft is the Amplify® GR 204 available from Dow Chemicals.

[0182] In further aspects, the ethylene polymers for use as the grafted host 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 host ethylene polymers have 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 yet other aspects, the substantially linear ethylene polymers and high densify polyethylene are utilized as host ethylene polymers.

[0183] In some aspects, the secondary7backing material is an extruded secondary backing material. In some aspects, it is contemplated that the secondary7backing material can be extruded or applied by any other technique known in the art. In some aspects, the secondary backing material may optionally include exemplary additives such as foaming agents, pH controllers, flame retardants, fillers, tackifiers, wetting agents, dispersing agents, anti-microbial agents, lubricants, dyes, anti-oxidants, and the like, which are well known to those skilled in the art. without loss of the characteristic properties.

[0184] In some aspects, the adhesive layer and the secondary- backing material are coextruded.

[0185] In some aspects, the secondary backing material comprises a spunbond material. In a further aspect, the spunbond material is a nonwoven spunbond material comprising polyester or a polyolefin. The spunbond material can be produced by depositing extruded, spun filaments onto a collecting belt in a uniform random manner followed by bonding the fibers. The fibers are separated during the w eb laying process by air jets or electrostatic charges. The collecting surface is usually perforated to prevent the air stream from deflecting and carrying the fibers in an uncontrolled manner. Bonding imparts strength and integrity7to the web by applying heated rolls or hot needles to partially melt the polymer and fuse the fibers together. Since molecular orientation increases the melting point, fibers that are not highly dray\n can be used as thermal binding fibers. In some aspect, the spunbond material can comprise a bi-component filament of a sheath-core type. In some aspects, the polymericcore component can have a higher melting point than the polymeric sheath component. In some aspects, the polymeric core component can comprise polyester, aliphatic polyamides, polyphenylene oxide and / or co-polymers or blends thereof. In yet other aspects, the polyester can comprise polyethylene terephthalate, polybutylene terephthalate, or polyparaphenylene terephthalamide. In yet other aspects, the polymeric core comprises polyethylene terephthalate. In further aspects, the sheath polymer can comprise a polyamide, polyethylene, or polyester. In yet further aspects, the sheath polymer comprises nylon. In still further aspects, the secondary backing material comprises a polyester as a core component and nylon as a sheath component.

[0186] In some aspects, the secondary backing material comprises a needlebond material (e.g.. structured needlebond). The needlebond material can have barbed needles penetrated therethrough to form a stabilized web structural integrity. The needlebond material can optionally be highly textured and have a coarse denier.

[0187] In some aspects, the secondary' backing material can comprise a polymer film comprising a thermoplastic material. In yet other aspects, the polymer film is a thermoplastic film. In other aspects, the polymer film comprises polymers and copolymers of polyethylene, polypropylene, polyurethane, polyester, polyvinylchloride, nylon and polyethylene vinyl acetate. In yet other aspects, the polymer film comprises polyethylene, polypropylene, polyurethane, polyester, or polyvinylchloride, or a combination thereof. In a yet further aspect, the polymer film is polyethylene. In yet further aspects, the polymer film is a combination of polyethylene and polyester.

[0188] In one aspect, the secondary backing material can further comprise one or more flame retardants sufficient to ensure the carpet structure satisfies the requirements of the radiant flux floor covering test according to the ASTM-E648 testing procedures. In particular, according to certain aspects, the carpets exhibit a Class 1 critical radiant flux of greater than 0.45 watts per cm2as measured according to ASTM-E648. According to other aspects, the carpets can exhibit a Class 2 critical radiant flux in the range of from 0.22 to 0.44 watts per cm2as measured according to ASTM-E648. In still further aspects, the carpets can exhibit an unclassifiable critical radiant flux of less than 0.22 watts per cm2as measured according to ASTM-E648.

[0189] Exemplar^' flame retardants that can be incorporated into the secondary backing materials include, without limitation, organo-phosphorous flame retardants, red phosphorous magnesium hydroxide, magnesium dihydroxide, hexabromocyclododecane, brominecontaining flame retardants, brominated aromatic flame retardants, melamine cyanurate, melamine polyphosphate, melamine borate, methylol and its derivatives, silicon dioxide, calcium carbonate, resourcinol bis-(diphenyl phosphate), brominated latex base, antimony trioxide, strontium borate, strontium phosphate, monomeric N-alkoxy hindered amine (NOR HAS), triazine and its derivatives, high aspect ratio talc, phosphated esters, organically modified nanoclays and nanotubes, non-organically modified nanoclays and nanotubes, ammonium polyphosphate, polyphosphoric acid, ammonium salt, triaryl phosphates, isopropylated triphenyl phosphate, phosphate esters, magnesium hydroxide, zinc borate, bentonite (alkaline activated nanoclay and nanotubes), organoclays, aluminum trihydrate (ATH). azodicarbonamide, diazenedicarboxamide, azodicarbonic acid diamide (ADC), triaryl phosphates, isopropylated triphenyl phosphate, triazine derivatives, alkaline activated organoclay and aluminum oxide. Any desired amount of flame retardant can be used in the secondary backing material and the selection of such amount will depend, in part, upon the particular flame retardant used and desired carpet applications. Such amounts can be readily determined through no more than routine experimentation.

[0190] Exemplary and non-limiting additional fillers that can be incorporated into the secondary backing materials can include calcium carbonate in a form different from oolitic aragonite, carbon-negative precipitated calcium carbonate, fly-ash, recycled calcium carbonate in a form different from oolitic aragonite, carbon-negative precipitated calcium carbonate, aluminum trihydrate, talc, nano-clay, barium sulfate, barite, barite glass fiber, glass powder, glass cullet, metal powder, alumina, hydrated alumina, clay, magnesium carbonate, calcium sulfate, silica, glass, fumed silica, carbon black, graphite, cement dust, feldspar, nepheline, magnesium oxide, zinc oxide, aluminum silicate, calcium silicate, titanium dioxide, titanates, glass microspheres, chalk, calcium oxide, and any combination thereof. In one aspect, the secondary backing material comprises inorganic filler with high heat content. In some aspects, it is for the filler to exhibit relatively high heat content. Examples of such fillers include, but are not limited to, calcium carbonate, aluminum trihydrate, talc, and barite. The exemplified high heat content fillers allow the extrudate to remain at elevated temperatures longer with the beneficial result of providing enhanced encapsulation and penetration. In this aspect, the high heat content fillers should be ground or precipitated to a size that can be conveniently incorporated in an extrusion coating melt stream. Exemplar}’ non-limiting particle sizes for the inorganic filler material can include particle sizes in the range of from about 1 to about 50 microns. Still further, it should also be understood that the filler component can be present in any desired amount. However, in anexemplary aspect, the filler is present in an amount in the range of from about 10 weight % to about 90 weight %, based upon the total weight of the secondary backing material, including exemplary amounts of about 15 weight %, 20 weight %, 25 weight %, 30 weight %, 35 weight %, 40 weight %, 45 weight %, 50 weight %, 55 weight %, 60 weight %, 65 weight %, 70 weight %. 75 weight %, 80 weight %, and about 85 weight %. Still further, the amount of filler present can be in any range derived from any two of the above stated weight percentages.

[0191] In still another aspect, the secondary backing material can further comprise one or more tackifying additives. The tackifier can for example be tall oil or rosin based or, alternatively, can be an aliphatic or aliphatic aromatic hydrocarbon blend resin. As the tackifier is an optional component, the amount of tackifier can be, when present, in the range of from greater than 0 weight percent up to and even exceeding about 50 weight % of the secondary backing material. For example, in one aspect, the amount of tackifier can be in the range of from about 5 weight % to about 45 weight %. In still another aspect, the amount of tackifier can be in the range of from about 10 weight % to about 20 weight %.

[0192] In some aspects, only the precoat layer, secondary' backing material, and adhesive layer comprises a carbon-negative material. In some aspects, only the primary backing material, secondary’ backing material, and adhesive layer comprises a water-absorbing particulate carbon-negative material.B. METHODS OF MAKING

[0193] In one aspect, disclosed herein are methods of making a carpet, the method comprising: a) providing a primary' backing material having a face side and an opposing back side, wherein the primary backing material comprises a plurality of fibers attached to the primary' backing material and extending from the face side of the primary backing material and exposed at the opposing back side of the primary backing material; b) attaching a precoat layer having a face side and an opposing back side to the opposing back side of the primary7backing material; c) attaching an adhesive layer having a face side and an opposing back side to the opposing back side of the precoat layer, wherein the adhesive layer comprises an adhesive composition comprising: i. a thermoplastic polyolefin; and ii. from about 0.1 % to about 75 % by weight of a particulate carbon-negative material; d) attaching a reinforcing layer having a face side and an opposing back side to the opposing back side of the adhesive layer; and e) attaching a secondary backing material having a face side and an opposing backside to the opposing back side of the reinforcing layer, wherein the secondary’ backing material comprises a thermoplastic material, thereby forming the carpet.

[0194] In one aspect, disclosed herein are methods of making a carpet, the method comprising: a) providing a primary backing material having a face side and an opposing back side, wherein the primary' backing material comprises a plurality7of fibers attached to the primary7backing material and extending from the face side of the primary backing material and exposed at the opposing back side of the primary backing material; b) attaching an adhesive layer having a face side and an opposing back side to the opposing back side of the primary7backing material, wherein the adhesive layer comprises an adhesive composition comprising: i. a thermoplastic polyolefin; and ii. from about 0.1 % to about 75 % by weight of a particulate carbon-negative material; c) attaching a reinforcing layer having a face side and an opposing back side to the opposing back side of the adhesive layer; and d) attaching a secondary7backing material having a face side and an opposing back side to the opposing back side of the reinforcing layer, wherein the secondary backing material comprises a thermoplastic material, thereby forming the carpet.

[0195] In one aspect, disclosed herein are methods of making a carpet, the method comprising: a) providing a primary backing material having a face side and an opposing back side, wherein the primary7backing material comprises a plurality7of fibers attached to the primary7backing material and extending from the face side of the primary backing material and exposed at the opposing back side of the primary backing material; b) attaching a precoat layer having a face side and an opposing back side to the opposing back side of the primary backing material; c) attaching an adhesive layer having a face side and an opposing back side to the opposing back side of the precoat layer, wherein the adhesive layer comprises an adhesive composition comprising: i. a thermoplastic polyolefin; and ii. from about 0. 1 % to about 75 % by weight of a particulate carbon-negative material; d) attaching a reinforcing layer having a face side and an opposing back side to the opposing back side of the adhesive layer, thereby forming the carpet.

[0196] The face of a tufted carpet can generally be made in three ways. First, for loop pile carpet, the yam loops formed in the tufting process are left intact. Second, for cut pile carpet, the yam loops are cut, either during tufting or after, to produce a pile of single yam ends instead of loops. Third, some carpet styles include both loop and cut pile. One variety of this hybrid is referred to as tip-sheared carpet where loops of differing lengths are tufted followed by shearing the carpet at a height so as to produce a mix of uncut, partially cut, andcompletely cut loops. Alternatively, the tufting machine can be configured so as to cut only some of the loops, thereby leaving a pattern of cut and uncut loops. Whether loop, cut, or a hybrid, the yam on the opposing back side of the primary backing material comprises tight, unextended loops. The combination of tufted yam and a primary7backing material without the application of an adhesive backing material or secondary backing material is referred to in the carpet industry as raw tufted carpet or greige goods. Greige goods become finished tufted carpet with the application of secondary backing materials or any other additional backings if present to the opposing back side of the primary' backing material. In some aspects, the greige goods become finished tufted carpet with the application of the adhesive layer, reinforcing layer, and a secondary backing material. Finished tufted carpet can be prepared as broad-loomed carpet in rolls typically 6 or 12 feet wide. In some other aspects, broadloom carpet can be prepared in rolls 13'6" and 15' feet wide.

[0197] In another aspect, any conventional tufting or needle-punching apparatus and / or stitch patterns can be used to make the carpets disclosed herein. Likewise, it does not matter whether tufted yam loops are left uncut to produce a loop pile; cut to make cut pile; or cut. partially cut and uncut to make a face texture known as tip sheared. After the yam is tufted or needle-punched into the primary backing material, the greige good can be conventionally rolled up with the opposing back side of the primary7backing component facing outward and held until it is transferred to the backing line.

[0198] FIG. 2 shows an exemplary system 200 for making the carpets disclosed herein. In one aspect, a carpet greige good 204 made by attaching a plurality of fibers to the primary7backing material and extending from the face side of the primary backing material is provided by roller 202, wherein the opposing back side of the primary7backing material is facing up. In some aspects, the optional precoat layer can be attached to the opposing back side of the primary backing material using, for example, roller applicator 206. In this exemplary system, the adhesive layer can then be attached to the opposing back side of the precoat layer or of the primary7backing material by extruder 210, followed by lamination via nip roller 218. An optional reinforcing layer 216 can be applied to the opposing backside of the adhesive layer during lamination, followed by cooling via cooling can roller 219. Finally, an optional secondary backing material can be attached to the opposing back side of the reinforcing layer by extruder 220, followed by lamination via nip roller 222, which adheres the reinforcing layer to the opposing back side of the adhesive layer and the face side of the secondary backing material, and cooling via cooling can roller 224.

[0199] The optional precoat layer can be applied to the carpet in many ways. For example, the precoat layer can be applied directly, such as with a roll over roller applicator, or a doctor blade. Alternatively, the precoat layer can be applied indirectly, such as with a pan applicator. It is contemplated that the amount of precoat layer applied and the concentration of the particles in the precoat layer can be varied depending on the desired processing and product parameters. In some aspects, the precoat layer is present in the carpet in an amount of about 30 ounces / sq. yard or less, about 29 ounces / sq. yard or less, about 28 ounce / sq. yard or less, about 27 ounce / sq. yard or less, about 26 ounce / sq. yard or less, about 25 ounce / sq. yard or less, about 24 ounce / sq. yard or less, about 23 ounce / sq. yard or less, about 22 ounce / sq. yard or less, about 21 ounce / sq. yard or less, about 20 ounce / sq. yard or less, about 19 ounces / sq. yard or less, about 18 ounces / sq. yard or less, about 17 ounces / sq. yard or less, about 16 ounces / sq. yard or less, about 15 ounces / sq. yard or less, about 14 ounces / sq. yard or less, about 13 ounces / sq. yard or less, or about 12 ounces / sq. yard or less. In an exemplary aspect, a thermoplastic dispersion present in the precoat layer is Vinnapas ® CA-5544 from Wacker. In yet other aspects, the latex present in the precoat layer is SBR based latex or any other latex disclosed herein.

[0200] After application of the precoat layer, heat can be applied to the opposing back side of the primary backing material so as to dry. melt, and / or cure the precoat layer. As a result, the loops of yam can be at least partially fixed to the primary backing material. Preferably, the heat is applied by passing the product through an oven.

[0201] In certain aspects, the adhesive layer is attached to the opposing back side of the precoat layer, followed by attaching a reinforcing layer to the opposing back side of the adhesive layer, and followed by attaching a secondary backing material to the opposing back side of the reinforcing layer. In such aspects, each of the layers can be sequentially extruded or laminated.

[0202] In some aspects, the adhesive layer is attached to the opposing back of the primary backing material, followed by attaching a reinforcing layer to the opposing back side of the adhesive layer, followed by attaching a secondary backing material to the opposing back side of the reinforcing layer. In such aspects, each of the layers can be sequentially extruded or laminated.

[0203] In some aspects, the adhesive layer is attached to the opposing back side of the precoat layer, followed by attaching a reinforcing layer to the opposing back side of the adhesive layer. In such aspects, each of the layers can be sequentially extruded or laminated.

[0204] In certain aspects, the adhesive layer, reinforcing layer, and secondary backing material are provided simultaneously and then co-laminated to the opposing back side of the precoat layer. In further aspects, the adhesive layer and the reinforcing layer are provided simultaneously and then co-laminated to the opposing back side of the precoat layer.

[0205] In other aspects, the reinforcing layer and the adhesive layer are provided simultaneously and then attached to the opposing back side of the precoat layer. In such aspects, the reinforcing layer and the adhesive layer can be co-laminated to the opposing back side of the precoat layer. In such aspects, the secondary backing material can be attached to the opposing back side of the reinforcing layer in a separate step.

[0206] In some aspects, the reinforcing layer and the adhesive layer are provided simultaneously and then attached to the opposing back side of the primary backing material. In such aspects, the reinforcing layer and the adhesive layer can be co-laminated to the opposing back side of the primary backing material. In such aspects, the secondary backing material can be attached to the opposing back side of the reinforcing layer in a separate step.

[0207] In some aspects, the secondary' backing material and the reinforcing layer are provided simultaneously and attached to the opposing back side of the adhesive layer. In such aspects, the secondary backing material and the reinforcing layer can be co-laminated to the opposing back side of the adhesive layer. In such aspects, the adhesive layer can be attached to the opposing back side of the precoat layer in a separate step.

[0208] After treatment with any precoat layer disclosed herein, an adhesive layer can be applied thereto. In some aspects, the adhesive layer disclosed herein can be rolled on the precoat layer. In other aspects, the method can comprise the use of an extruded sheet of a thermoplastic material. In some aspects, a molten thermoplastic material can be extruded through a die so as to make a sheet which is as wide as the carpet.

[0209] Exemplary extrusion coating configurations can include, without limitation, a monolayer T-type die, single-lip die co-extrusion coating, dual-lip die co-extrusion coating, a coat hanger die, and multiple stage extrusion coating. Preferably, the extrusion coating equipment is configured to apply a total coating weight of from about 4 to about 60 ounces / yd2(OSY), including exemplary amounts of 5, 10, 15, 20, 25, 30, 35, 40, 45, 50 and 55 ounces / yd2(OSY), and any range of coating weights derived from these values. To that end, it should be understood that the desired coating weight of the extrusion coated layerswill depend, at least in part, upon the amount of any flame retardants or inorganic fillers in the extrudate.

[0210] The extrusion coating melt temperature principally depends on the particular composition of the adhesive layer being extruded. When the adhesive layer described herein is extruded, the extrusion coating melt temperature can be greater than about 350° F and. in some aspects, in the range of from 350° F to 650° F. In another aspect, the melt temperature can be in the range of from 375° F to 600° F. Alternatively, the melt temperature can be in the range of from 400° F to 550° F.

[0211] In some aspects, a reinforcing layer is attached to the opposing back side of the adhesive layer to provide dimensional stability- to the carpet. The reinforcing layer can be laminated onto the opposing back side of the adhesive layer or applied as a sheet, such as a fiberglass mat.

[0212] After attachment of the reinforcing layer, the optional secondary backing material can be attached to the opposing back side of the reinforcing layer through various methods. In some aspects, the secondary backing material disclosed herein can be rolled onto the opposing back side of the reinforcing layer. In other aspects, the method can comprise the use of an extruded sheet of a thermoplastic material. In some aspects, a molten thermoplastic material can be extruded through a die so as to make a sheet which is as wide as the carpet.

[0213] In some aspects, lamination can be done at a temperature from about 250 to about 400 °F, including exemplary values of about 260 °F, about 270 °F, about 280 °F, about 290 °F, about 300 °F. about 310 °F, about 320 °F, about 330 °F, about 340 °F, about 350 °F, about 360 °F, about 370 °F, about 380 °F, and about 390 °F.

[0214] In certain aspects, the gap between two rolls can be any gap commonly utilized by lamination industry7. In certain aspects, the gap can be between about 10 mil to about 250 mils, including exemplary values of about 15 mil, about 18 mil. about 20 mil, about 30 mil, about 50 mil. about 60 mil, about 70 mil, about 80 mil, about 90 mil, about 100 mil, about110 mil, about 120 mil, about 130 mil, about 140 mil, about 150 mil, about 160 mil, about170 mil, about 180 mil, about 190 mil, about 200 mil, about 210 mil, about 220 mil, about230 mil, and about 240 mil.

[0215] In still further aspects, any pressure usually used in lamination industry- can be applied. In some aspects, the pressure can be between 6,000 force lbs to about 9,000 forcelbs. including exemplary values of about 6,500 force lbs, about 7.000 force lbs, about 7,500 force lbs, about 8,000 force lbs, and about 8,500 force lbs.

[0216] Any known in the art lamination equipment can be used, for example, equipment sold by Union Tool Corporation. An exemplar}- lamination equipment that can be used is a Union Tool Hot Roll Laminator MD 20962.

[0217] ASPECTS

[0218] In view of the disclosure herein below are described certain more particularly described aspects of the disclosed carpets and methods. These particularly recited aspects should not however be interpreted to have any limiting effect on any different claims containing different or more general teachings described herein, or that the “particular” aspects are somehow limited in some way other than the inherent meanings of the language and formulas literally used therein.

[0219] Aspect 1: A carpet comprising: a) a primary backing material having a face side and an opposing back side; b) a plurality of fibers attached to the primary backing material and extending from the face side of the primary backing material and exposed at the opposing back side of the primary backing material; c) a precoat layer having a face side and an opposing back side, wherein the face side of the precoat layer is attached to the opposing back side of the primary backing material; d) an adhesive layer having a face side and an opposing back side, wherein the face side of the adhesive layer is attached to the opposing back side of the precoat layer, wherein the adhesive layer comprises an adhesive composition comprising: i. a thermoplastic polyolefin; and ii. from about 0. 1 % to about 75 % by weight of a particulate carbon-negative material; e) a reinforcing layer having a face side and an opposing back side, wherein the face side of the reinforcing layer is attached to the opposing back side of the adhesive layer; and f) a secondary backing material having a face side and an opposing back side, wherein the face side of the secondary backing material is attached to the opposing back side of the reinforcing layer, wherein the secondary backing material comprises a thermoplastic polyolefin.

[0220] Aspect 2: A carpet comprising: a) a primary backing material having a face side and an opposing back side; b) a plurality of fibers attached to the primary backing material and extending from the face side of the primary backing material and exposed at the opposing back side of the primary backing material: c) an adhesive layer having a face side and an opposing back side, wherein the face side of the adhesive layer is attached to the opposingback side of the primary backing material, wherein the adhesive layer comprises an adhesive composition comprising: i. a thermoplastic polyolefin; and ii. from about 0. 1 % to about 75 % by weight of a particulate carbon-negative material; d) a reinforcing layer having a face side and an opposing back side, wherein the face side of the reinforcing layer is attached to the opposing back side of the adhesive layer; and e) a secondary backing material having a face side and an opposing back side, wherein the face side of the secondary backing material is attached to the opposing back side of the reinforcing layer, wherein the secondary backing material comprises a thermoplastic polyolefin.

[0221] Aspect 3: A carpet comprising: a) a primary backing material having a face side and an opposing back side; b) a plurality of fibers attached to the primary backing material and extending from the face side of the primary backing material and exposed at the opposing back side of the primary backing material; c) a precoat layer having a face side and an opposing back side, wherein the face side of the precoat layer is attached to the opposing back side of the primary backing material: d) an adhesive layer having a face side and an opposing back side, wherein the face side of the adhesive layer is attached to the opposing back side of the precoat layer, wherein the adhesive layer comprises an adhesive composition comprising: i. a thermoplastic polyolefin; and ii. from about 0.1 % to about 75 % by weight of a particulate carbon-negative material; and e) a reinforcing layer having a face side and an opposing back side, wherein the face side of the reinforcing layer is attached to the opposing back side of the adhesive layer.

[0222] Aspect 4: The carpet of any of aspects 1-3, wherein the adhesive composition comprises from about 10 % to about 75 % by weight of a particulate carbon-negative material.

[0223] Aspect 5: The carpet of any of aspects 1-3, wherein the adhesive composition comprises from about 1.5 % to about 20 % by weight of a particulate carbon-negative material.

[0224] Aspect 6: The carpet of any of aspects 1-5, wherein the particulate carbonnegative material is oolitic aragonite, carbon-negative precipitated calcium carbonate, biochar, or a composite material comprising plastic matter and organic matter.

[0225] Aspect 7: The carpet of aspect 6, wherein the particulate carbon-negative material is oolitic aragonite.

[0226] Aspect 8: The carpet of aspect 6, wherein the particulate carbon-negative material is a composite material comprising plastic matter and organic matter.

[0227] Aspect 9: The carpet of any of aspects 1 -4 wherein the particulate carbonnegative material is oolitic aragonite.

[0228] Aspect 10: The carpet of any of aspects 1-3 or 5, wherein the particulate carbonnegative material is a composite material comprising plastic matter and organic matter.

[0229] Aspect 11: The carpet of any of aspect 10, wherein the composite material comprising plastic matter and organic matter is formed by mixing while heating the organic matter and plastic matter under shear forces.

[0230] Aspect 12: The carpet of any of aspects 1-6, wherein the particulate carbonnegative material is biochar.

[0231] Aspect 13: The carpet of any of aspects 1-2 or 4-12, wherein the secondary backing material further comprises a water-absorbing particulate carbon-negative material in a weight that is less than the weight of a water-absorbing particulate carbon-negative material in the adhesive layer.

[0232] Aspect 14: The carpet of any of aspects 1-2 or 4-13, wherein the particulate carbon-negative material in the secondary backing material is oolitic aragonite, carbonnegative precipitated calcium carbonate , biochar, or a composite material comprising plastic matter and organic matter.

[0233] Aspect 15: The carpet of any of aspects 1-2 or 4-14, wherein the particulate carbon-negative material in the secondary7backing material is oolitic aragonite.

[0234] Aspect 16: The carpet of any of aspects 1-2 or 4-15, wherein the particulate carbon-negative material in the secondary backing material is a composite material comprising plastic matter and organic matter.

[0235] Aspect 17: The carpet of aspect 16, wherein the composite material comprising plastic matter and organic matter is formed by mixing while heating the organic matter and plastic matter under shear forces.

[0236] Aspect 18: The carpet of any of aspects 1-2 or 4-17, wherein the particulate carbon-negative material in the secondary backing material is biochar.

[0237] Aspect 19: The carpet of any of aspects 1-2 or 4-18, wherein the secondary’ backing material does not comprise a particulate carbon-negative material.

[0238] Aspect 20: The carpet of any of aspects 1-19, wherein the particulate carbonnegative material is a water-absorbing particulate carbon-negative material.

[0239] Aspect 21: The carpet of any of aspects 1-20, wherein the thermoplastic polyolefin is a carbon-negative material.

[0240] Aspect 22: The carpet of any of aspects 1-21, wherein the secondary backing material is an extruded secondary backing material.

[0241] Aspect 23: The carpet of any of aspects 1-22, wherein the reinforcing layer is a fiberglass scrim.

[0242] Aspect 24: The carpet of any of aspects 1, 3, or 4-23, wherein the precoat layer comprises latex.

[0243] Aspect 25: The carpet of any of aspects 1. 3, or 4-24, wherein the precoat layer does not comprise a particulate carbon-negative material.

[0244] Aspect 26: The carpet of any of aspects 1, 3, or 4-25-, wherein the precoat layer comprises a particulate carbon-negative material.

[0245] Aspect 27: The carpet of aspect 26, wherein the particulate carbon-negative material is a water-absorbing particulate carbon-negative material.

[0246] Aspect 28: The carpet of aspect 26 or 27, wherein the particulate carbon-negative material is oolitic aragonite, carbon-negative precipitated calcium carbonate, biochar, or a composite material comprising plastic matter and organic matter.

[0247] Aspect 29: A method of making a carpet comprising: a) providing a primary backing material having a face side and an opposing back side, wherein the primary backing material comprises a plurality of fibers attached to the primary backing material and extending from the face side of the primary backing material and exposed at the opposing back side of the primary backing material; b) attaching a precoat layer having a face side and an opposing back side to the opposing back side of the primary backing material; c) attaching an adhesive layer having a face side and an opposing back side to the opposing back side of the precoat layer, wherein the adhesive layer comprises an adhesive composition comprising: i. a thermoplastic polyolefin; and ii. from about 0. 1 % to about 75 % by weight of aparticulate carbon-negative material; d) attaching a reinforcing layer having a face side and an opposing back side to the opposing back side of the adhesive layer; and e) attaching a secondary backing material having a face side and an opposing back side to the opposing back side of the reinforcing layer, wherein the secondary backing material comprises a thermoplastic material, thereby forming the carpet.

[0248] Aspect 30: A method of making a carpet comprising: a) providing a primary backing material having a face side and an opposing back side, wherein the primary backing material comprises a plurality of fibers attached to the primary backing material and extending from the face side of the primary backing material and exposed at the opposing back side of the primary backing material: b) attaching an adhesive layer having a face side and an opposing back side to the opposing back side of the primary backing material, wherein the adhesive layer comprises an adhesive composition comprising: i. a thermoplastic polyolefin; and ii. from about 0. 1 % to about 75 % by weight of a particulate carbon-negative material; d) attaching a reinforcing layer having a face side and an opposing back side to the opposing back side of the adhesive layer; and e) attaching a secondary backing material having a face side and an opposing back side to the opposing back side of the reinforcing layer, wherein the secondary' backing material comprises a thermoplastic material, thereby forming the carpet.

[0249] Aspect 31 : A method of making a carpet comprising: a) providing a primary backing material having a face side and an opposing back side, wherein the primary backing material comprises a plurality of fibers attached to the primary backing material and extending from the face side of the primary backing material and exposed at the opposing back side of the primary backing material; b) attaching a precoat layer having a face side and an opposing back side to the opposing back side of the primary backing material; c) attaching an adhesive layer having a face side and an opposing back side to the opposing back side of the precoat layer, wherein the adhesive layer comprises an adhesive composition comprising: i. a thermoplastic polyolefin; and ii. from about 0.1 % to about 75 % by weight of a particulate carbon-negative material; and d) attaching a reinforcing layer having a face side and an opposing back side to the opposing back side of the adhesive layer, thereby forming the carpet.

[0250] Aspect 32: The method of aspect 29, wherein the adhesive composition comprises from about 10 % to about 75 % by weight of a particulate carbon-negative material.

[0251] Aspect 33: The method of aspect 29, wherein the adhesive composition comprises from about 1.5 % to about 20 % by weight of a particulate carbon-negative material.

[0252] Aspect 34: The method of any of aspects 29-31, wherein the particulate carbonnegative material is oolitic aragonite, carbon-negative precipitated calcium carbonate, biochar, a carbon-negative polyethylene resin, or a composite material comprising plastic matter and organic matter.

[0253] Aspect 35: The method of aspect 32, wherein the particulate carbon-negative material is oolitic aragonite.

[0254] Aspect 36: The method of aspect 32, wherein the particulate carbon-negative material is a composite material comprising plastic matter and organic matter.

[0255] Aspect 37: The method of aspect 30, wherein the particulate carbon-negative material is oolitic aragonite.

[0256] Aspect 38: The method of aspect 31, wherein the particulate carbon-negative material is a composite material comprising plastic matter and organic matter.

[0257] Aspect 39: The method of aspect 36, wherein the composite material comprising plastic matter and organic matter is formed by mixing while heating the organic matter and plastic matter under shear forces.

[0258] Aspect 40: The method of any of aspects 29-31, wherein the particulate carbonnegative material is biochar.

[0259] Aspect 41: The method of any of aspects 29-30 and 32-40, wherein the secondary backing material further comprises a particulate carbon-negative material in a weight that is less than the weight of a particulate carbon-negative material in the adhesive layer.

[0260] Aspect 42: The method of aspect 41, wherein the particulate carbon-negative material in the secondary backing material is oolitic aragonite, carbon-negative precipitated calcium carbonate, biochar, or a composite material comprising plastic matter and organic matter.

[0261] Aspect 43: The method of aspect 42, wherein the particulate carbon-negative material in the secondary’ backing material is oolitic aragonite.

[0262] Aspect 44: The method of aspect 42, wherein the particulate carbon-negative material in the secondary backing material is a composite material comprising plastic matter and organic matter.

[0263] Aspect 45: The method of aspect 44, wherein the composite material comprising plastic matter and organic matter is formed by mixing while heating the organic matter and plastic matter under shear forces.

[0264] Aspect 46: The method of aspect 42, wherein the particulate carbon-negative material in the secondary backing material is biochar.

[0265] Aspect 47: The method of aspect 42, wherein the secondary backing material does not comprise a particulate carbon-negative material.

[0266] Aspect 48: The method of any of aspects 29-47, wherein the particulate carbonnegative material is a water-absorbing particulate carbon-negative material.

[0267] Aspect 49: The method of any of aspects 29-48, wherein the thermoplastic polyolefin is a carbon-negative material.

[0268] Aspect 50: The method of any of aspects 29-49, wherein the adhesive layer is an extruded adhesive layer.

[0269] Aspect 51: The method of any of aspects 29-50, wherein the secondary' backing material is an extruded secondary backing material.

[0270] Aspect 52: The method of any of aspects 29-51, wherein the reinforcing layer is a fiberglass scrim.

[0271] Aspect 53: The method of any of aspects 29 or 31 -52, wherein the precoat layer comprises latex.

[0272] Aspect 54: The method of any of aspects 29 or 31-53, wherein the precoat layer does not comprise a particulate carbon-negative material.

[0273] Aspect 55: The method of any of aspects 29 or 31-54, wherein the precoat layer comprises a particulate carbon-negative material.

[0274] Aspect 56: The method of aspect 55, wherein the particulate carbon-negative material is a water-absorbing particulate carbon-negative material.

[0275] Aspect 57: The method of aspect 55 or 56, wherein the particulate carbonnegative material is oolitic aragonite, carbon-negative precipitated calcium carbonate, biochar, or a composite material comprising plastic matter and organic matter.

[0276] Aspect 58: The carpet of any of aspects 1-28, wherein the adhesive layer is an extruded adhesive layer.EXAMPLES

[0277] Moisture regain of particulate carbon-negative materials is shown in Table 1 below. Mined calcium carbonate (HCP15G) was used as the control and compared with two different grades of oolitic aragonite (OceanCal 5U and OceanCal 10S) and composite material comprising plastic matter and organic matter (UBQ). A sample of material was dried at 105 °C for 1 hour, followed by weighing. The sample was then subj ected to 90 % relative humidity at 90 °F for 16 days. Moisture regain at day 16 was higher for both samples of oolitic aragonite and composite material comprising plastic matter and organic matter compared to mined calcium carbonate.Table 1

Claims

CLAIMSWhat is claimed is:

1. A carpet comprising: a) a primary backing material having a face side and an opposing back side; b) a plurality of fibers attached to the primary backing material and extending from the face side of the primary backing material and exposed at the opposing back side of the primary backing material; c) a precoat layer having a face side and an opposing back side, wherein the face side of the precoat layer is attached to the opposing back side of the primary backing material; d) an adhesive layer having a face side and an opposing back side, wherein the face side of the adhesive layer is attached to the opposing back side of the precoat layer, wherein the adhesive layer comprises an adhesive composition comprising: i. a thermoplastic polyolefin; and ii. from about 0. 1 % to about 75 % by weight of a particulate carbonnegative material; e) a reinforcing layer having a face side and an opposing back side, wherein the face side of the reinforcing layer is attached to the opposing back side of the adhesive layer; and f) a secondary backing material having a face side and an opposing back side, wherein the face side of the secondary' backing material is attached to the opposing back side of the reinforcing layer, wherein the secondary backing material comprises a thermoplastic polyolefin.

2. The carpet of claim 1, wherein the adhesive composition comprises from about 10 % to about 75 % by weight of a particulate carbon-negative material.

3. The carpet of claim 1, wherein the adhesive composition comprises from about 1.5 % to about 20 % by w eight of a particulate carbon-negative material.

4. The carpet of claim 1, wherein the particulate carbon-negative material is oolitic aragonite, carbon-negative precipitated calcium carbonate, biochar, a carbon-negative polyethylene resin, or a composite material comprising plastic matter and organic matter.

5. The carpet of claim 4, wherein the particulate carbon-negative material is oolitic aragonite.

6. The carpet of claim 4, wherein the particulate carbon-negative material is a composite material comprising plastic matter and organic matter.

7. The carpet of claim 2, wherein the particulate carbon-negative material is oolitic aragonite.

8. The carpet of claim 3, wherein the particulate carbon-negative material is a composite material comprising plastic matter and organic matter.

9. The carpet of claim 4, wherein the composite material comprising plastic matter and organic matter is formed by mixing while heating the organic matter and plastic matter under shear forces.

10. The carpet of claim 4, wherein the particulate carbon-negative material is biochar.

11. The carpet of claim 1, wherein the secondary backing material further comprises a water-absorbing particulate carbon-negative material in a weight that is less than the weight of a water-absorbing particulate carbon-negative material in the adhesive layer.

12. The carpet of claim 11, wherein the particulate carbon-negative material in the secondary backing material is oolitic aragonite, carbon-negative precipitated calcium carbonate, a synthetic calcium carbonate, biochar, or a composite material comprising plastic matter and organic matter.

13. The carpet of claim 12, wherein the particulate carbon-negative material in the secondary backing material is oolitic aragonite.

14. The carpet of claim 12, wherein the particulate carbon-negative material in the secondary' backing material is a composite material comprising plastic matter and organic matter.

15. The carpet of claim 14. wherein the composite material comprising plastic matter and organic matter is formed by mixing while heating the organic matter and plastic matter under shear forces.

16. The carpet of claim 12. wherein the particulate carbon-negative material in the secondary backing material is biochar.

17. The carpet of claim 1, wherein the secondary backing material does not comprise a particulatecarbon-negative material.

18. The carpet of claim 1, wherein the particulatecarbon-negative material is a water-absorbing particulate carbon-negative material.

19. The carpet of claim 1, wherein the thermoplastic polyolefin is a carbonnegative material.

20. The carpet of claim 1, wherein the adhesive layer is an extruded adhesive layer.

21. The carpet of claim 1, wherein the secondary backing material is an extruded secondary backing material.

22. The carpet of claim 1, wherein the reinforcing layer is a fiberglass scrim.

23. The carpet of claim 1, wherein the precoat layer comprises latex.

24. The carpet of claim 1, wherein the precoat layer does not comprise a particulate carbon-negative material.

25. The carpet of claim 1, wherein the precoat layer comprises a particulate carbon-negative material.

26. The carpet of claim 25. wherein the particulate carbon-negative material is a water-absorbing particulate carbon-negative material.

27. The carpet of claim 25, wherein the particulate carbon-negative material is oolitic aragonite, carbon-negative precipitated calcium carbonate, biochar, or a composite material comprising plastic matter and organic matter.

28. A method of making a carpet comprising:a) providing a primary backing material having a face side and an opposing back side, wherein the primary backing material comprises a plurality of fibers attached to the primary backing material and extending from the face side of the primary backing material and exposed at the opposing back side of the primary backing material; b) attaching a precoat layer having a face side and an opposing back side to the opposing back side of the primary backing material; c) attaching an adhesive layer having a face side and an opposing back side to the opposing back side of the precoat layer, wherein the adhesive layer comprises an adhesive composition comprising: i. a thermoplastic polyolefin; and ii. from about 0. 1 % to about 75 % by weight of a particulate carbonnegative material; d) attaching a reinforcing layer having a face side and an opposing back side to the opposing back side of the adhesive layer; and e) attaching a secondary backing material having a face side and an opposing back side to the opposing back side of the reinforcing layer, wherein the secondary backing material comprises a thermoplastic material, thereby forming the carpet.

29. The method of claim 28, wherein the adhesive composition comprises from about 10 % to about 75 % by weight of a particulate carbon-negative material.

30. The method of claim 28, wherein the adhesive composition comprises from about 1.5 % to about 20 % by weight of a particulate carbon-negative material.

31. The carpet of method of claim 28, wherein the particulate carbon-negative material is oolitic aragonite, carbon-negative precipitated calcium carbonate, biochar, a carbon-negative polyethylene resin, or a composite material comprising plastic matter and organic matter.

32. The method of claim 31, wherein the particulate carbon-negative material is oolitic aragonite.

33. The method of claim 31, wherein the particulate carbon-negative material is a composite material comprising plastic matter and organic matter.

34. The method of claim 29, wherein the particulate carbon-negative material is oolitic aragonite.

35. The method of claim 30, wherein the particulate carbon-negative material is a composite material comprising plastic matter and organic matter.

36. The method of claim 35, wherein the composite material comprising plastic matter and organic matter is formed by mixing while heating the organic matter and plastic matter under shear forces.

37. The method of claim 31, wherein the particulate carbon-negative material is biochar.

38. The method of claim 28, wherein the secondary backing material further comprises a particulate carbon-negative material in a weight % that is less than the weight % of particulate carbon-negative material in the adhesive layer.

39. The method of claim 38, wherein the particulate carbon-negative material in the secondary backing material is oolitic aragonite, carbon-negative precipitated calcium carbonate, biochar, or a composite material comprising plastic matter and organic matter.

40. The method of claim 39, wherein the particulate carbon-negative material in the secondary backing material is oolitic aragonite.

41. The method of claim 39, wherein the particulate carbon-negative material in the secondary’ backing material is a composite material comprising plastic matter and organic matter.

42. The method of claim 41, wherein the composite material comprising plastic matter and organic matter is formed by mixing while heating the organic matter and plastic matter under shear forces.

43. The method of claim 38, wherein the particulate carbon-negative material in the secondary' backing material is biochar.

44. The method of claim 28, wherein the secondary backing material does not comprise a particulate carbon-negative material.

45. The method of claim 28, wherein the particulate carbon-negative material is a water-absorbing particulate carbon-negative material.

46. The method of claim 28, wherein the thermoplastic polyolefin is a carbon negative material.

47. The method of claim 28, wherein the adhesive layer is an extruded adhesive layer.

48. The method of claim 28, wherein the secondary backing material is an extruded secondary backing material.

49. The method of claim 28, wherein the reinforcing layer is a fiberglass scrim.

50. The method of claim 28, wherein the precoat layer comprises latex.

51. The method of claim 28, wherein the precoat layer does not comprise a particulate carbon-negative material.

52. The method of claim 28, wherein the precoat layer comprises a filler comprising a particulate carbon-negative material.

53. The method of claim 52, wherein the particulate carbon-negative material is a water-absorbing particulate carbon-negative material.

54. The method of claim 52, wherein the particulate carbon-negative material is oolitic aragonite, carbon-negative precipitated calcium carbonate, biochar, or a composite material comprising plastic matter and organic matter.

55. A carpet comprising: a) a primary backing material having a face side and an opposing back side; b) a plurality of fibers attached to the primary backing material and extending from the face side of the primary backing material and exposed at the opposing back side of the primary backing material;c) an adhesive layer having a face side and an opposing back side, wherein the face side of the adhesive layer is attached to the opposing back side of the primary backing material, wherein the adhesive layer comprises an adhesive composition comprising: i. a thermoplastic polyolefin; and ii. from about 0. 1 % to about 75 % by weight of a particulate carbonnegative material; d) a reinforcing layer having a face side and an opposing back side, wherein the face side of the reinforcing layer is attached to the opposing back side of the adhesive layer; and e) a secondary backing material having a face side and an opposing back side, wherein the face side of the secondary backing material is attached to the opposing back side of the reinforcing layer, wherein the secondary7backing material comprises a thermoplastic polyolefin.

56. A carpet comprising: a) a primary7backing material having a face side and an opposing back side; b) a plurality of fibers attached to the primary backing material and extending from the face side of the primary backing material and exposed at the opposing back side of the primary backing material; c) a precoat layer having a face side and an opposing back side, wherein the face side of the precoat layer is attached to the opposing back side of the primary7backing material; d) an adhesive layer having a face side and an opposing back side, wherein the face side of the adhesive layer is attached to the opposing back side of the precoat layer, wherein the adhesive layer comprises an adhesive composition comprising: i. a thermoplastic polyolefin; and ii. from about 0. 1 % to about 75 % by yveight of a particulate carbonnegative material; ande) a reinforcing layer having a face side and an opposing back side, wherein the face side of the reinforcing layer is attached to the opposing back side of the adhesive layer.

57. A method of making a carpet comprising: a) providing a primary backing material having a face side and an opposing back side, wherein the primary backing material comprises a plurality' of fibers attached to the primary backing material and extending from the face side of the primary backing material and exposed at the opposing back side of the primary' backing material; b) attaching an adhesive layer having a face side and an opposing back side to the opposing back side of the primary' backing material, wherein the adhesive layer comprises an adhesive composition comprising: i. a thermoplastic polyolefin; and ii. from about 0.1 % to about 75 % by weight of a particulate carbon-negative material; c) attaching a reinforcing layer having a face side and an opposing back side to the opposing back side of the adhesive layer; and d) attaching a secondary' backing material having a face side and an opposing back side to the opposing back side of the reinforcing layer, wherein the secondary backing material comprises a thermoplastic material, thereby forming the carpet.

58. A method of making a carpet comprising: a) providing a primary backing material having a face side and an opposing back side, wherein the primary' backing material comprises a plurality' of fibers attached to the primary backing material and extending from the face side of the primary' backing material and exposed at the opposing back side of the primary backing material; b) attaching a precoat layer having a face side and an opposing back side to the opposing back side of the primary backing material; c) attaching an adhesive layer having a face side and an opposing back side to the opposing back side of the precoat layer, wherein the adhesive layer comprises an adhesive composition comprising:i. a thermoplastic polyolefin; and ii. from about 0. 1 % to about 75 % by weight of a particulate carbonnegative material; d) attaching a reinforcing layer having a face side and an opposing back side back side of the adhesive layer, thereby forming the carpet.

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