Abstract: Methods and treatment compositions for imparting durable antimicrobial properties to carpet are provided. The method includes applying a composition comprising a first antimicrobial compound and a fluoropolymer to the carpet substrate. The carpet substrate may be steamed thereafter. The treatment composition may comprise a fluoropolymer, an antimicrobial compound selected from a group consisting of zinc pyrithione, a silver-containing antimicrobial compound and combinations thereof, and a foamer. Carpet products treated with the treatment composition or treated in accordance with the methods are also provided.

Abstract: The embodiments disclosed herein relate to thermoplastic polymer compositions that comprise a thermoplastic and nucleating agents, such as silica-containing nucleating agents. The polymer compositions provide improved properties relating to processing, dimensional and thermal stability, improved crystalline structure, and flame retardant properties. The thermoplastic polymer compositions are useful, for example, for carpet backing applications. It is a further feature of the embodiments to provide carpet backing compositions and carpet tiles prepared using the thermoplastic polymer composition, as well as methods of making the carpet tiles.

Abstract: The present application provides a yarn accumulator for use with a yarn sausage in a heat setting line. The yarn applicator may include a sled in contact with the yarn sausage and a tensioning device in communication with the sled. The tensioning device applies a variable tension to the sled based upon the length of the yarn sausage. The tensioning device may include a sled pulley in communication with the sled, a ratioed pulley set in communication with the sled pulley, a counterweight pulley in communication with the ratioed pulley set, and a counterweight in communication with the counterweight pulley.

Abstract: Methods and treatment compositions for imparting durable antimicrobial properties to carpet are provided. The method includes applying a composition comprising a first antimicrobial compound and a fluoropolymer to the carpet substrate. The carpet substrate may be steamed thereafter. The treatment composition may comprise a fluoropolymer, an antimicrobial compound selected from a group consisting of zinc pyrithione, a silver-containing antimicrobial compound and combinations thereof, and a foamer. Carpet products treated with the treatment composition or treated in accordance with the methods are also provided.

Abstract: Methods and treatment compositions for imparting durable antimicrobial properties to carpet are provided. The method includes applying a composition comprising a first antimicrobial compound and a fluoropolymer to the carpet substrate. The carpet substrate may be steamed thereafter. The treatment composition may comprise a fluoropolymer, an antimicrobial compound selected from a group consisting of zinc pyrithione, a silver-containing antimicrobial compound and combinations thereof, and a foamer. Carpet products treated with the treatment composition or treated in accordance with the methods are also provided.

Abstract: Embodiments relate to a relatively rapid transesterification process including transesterifying condensation polymers such as polyethylene terephthalate (PET), or other polyesters used in commerce, with a modifying monomer mix containing other monomers to manufacture new polymers containing the pre-condensed moieties. The process preferably only involves transesterification as a reaction mechanism. The process preferably produces a rapid buildup of molecular weight and/or polymer uniformity by the high temperature transesterification of the condensation polymer with the modifying monomer mixture. The process can be performed in any suitable vessel including an extrusion line, and it has the advantage of greatly reduced cycle times over currently used condensation polymer utilization processes such as the recycling of PET into other materials.

Abstract: A method for binding a greige carpet and a secondary backing material using a hot melt adhesive is disclosed. A heated application roll may be provided and the secondary backing material may be contacted with the hot melt adhesive and greige carpet and pressed against the heated application roll.

Abstract: The present application provides a yarn accumulator for use with a yarn sausage in a heat setting line. The yarn applicator may include a sled in contact with the yarn sausage and a tensioning device in communication with the sled. The tensioning device applies a variable tension to the sled based upon the length of the yarn sausage. The tensioning device may include a sled pulley in communication with the sled, a ratioed pulley set in communication with the sled pulley, a counterweight pulley in communication with the ratioed pulley set, and a counterweight in communication with the counterweight pulley.

Abstract: A lightweight carpet product includes a greige carpet having a primary backing and tufted fibers, a secondary backing including a nonwoven textile of synthetic fibers, and a thermoplastic adhesive composition adhered to the greige carpet and the secondary backing. The thermoplastic adhesive composition includes a modified polyethylene terephthalate (PET) having a crystallinity less than unmodified PET and a melting point from about 90° C. to about 150° C., and a particulate filler. Methods of manufacture include using a thermoplastic adhesive composition to adhere a greige carpet to a secondary backing to form a lightweight carpet product.

Abstract: A method for binding a greige carpet and a secondary backing material using a hot melt adhesive is disclosed. A heated application roll may be provided and the secondary backing material may be contacted with the hot melt adhesive and greige carpet and pressed against the heated application roll.

Abstract: A method for binding a greige carpet and a secondary backing material using a hot melt adhesive is disclosed. A heated application roll may be provided and the secondary backing material may be contacted with the hot melt adhesive and greige carpet and pressed against the heated application roll.

Abstract: Loop backed carpet tiles and methods of producing a carpet tile having a loop backing are provided. In one embodiment, the method includes applying a precoat adhesive, such as a latex, to the base of a carpet substrate; curing the precoat adhesive onto the carpet substrate; applying a lamination adhesive, which may be an ethyl vinyl acetate or a styrene-acrylate adhesive, onto the precoated carpet substrate, the lamination adhesive having an activation temperature at which the lamination adhesive is operable for lamination; and applying and laminating a backing fabric comprising loops to the precoated carpet substrate via the lamination adhesive after the lamination adhesive applied to the precoated carpet substrate is heated to the activation temperature.

Abstract: A carpet tile is provided that includes a face fabric having a top surface and a base, and a dimensionally-stabilized non-woven cushion material having a stabilizing material incorporated therein, incorporated thereonto or a combination thereof. The dimensionally-stabilized non-woven cushion material may be attached to the face fabric such that the dimensionally-stabilized non-woven cushion material provides dimensional stability to the face fabric. Methods of manufacturing dimensionally-stabilized cushioned carpet tile are also provided.

Abstract: Carpet products having antimicrobial properties and methods of manufacturing the same are provided. The carpet product includes a face fabric having a top surface and a base, and a pre-treated stabilizing material attached to the base of the face fabric. The pre-treated stabilizing material may have an antimicrobial compound coated thereonto or physically incorporated.

Abstract: Methods and treatment compositions for imparting durable antimicrobial properties to carpet are provided. The method includes applying a composition comprising a first antimicrobial compound and a fluoropolymer to the carpet substrate. The carpet substrate may be steamed thereafter. The treatment composition may comprise a fluoropolymer, an antimicrobial compound selected from a group consisting of zinc pyrithione, a silver-containing antimicrobial compound and combinations thereof, and a foamer. Carpet products treated with the treatment composition or treated in accordance with the methods are also provided.