Abstract: An example method for forming a pile fabric includes: providing a primary backing material (configured as a sheet), a layer of thermoplastic material (disposed at the back side of the primary backing material), and a plurality of pile tufts extending through the primary backing material and at least partially into the layer of thermoplastic material with back stitch portions of the pile tufts being disposed at the back side of the primary backing material; and heating only the back of the pile fabric to melt the back stitch portions of the pile tufts and the layer of thermoplastic material to form a melt bond disposed at the back side of the primary backing material to secure the pile tufts to the primary backing material.

Abstract: Secondary carpet backings woven in a flat weave construction from warp tapes and multifilament picks with 50 to about 100% theoretical coverage in the warp but less than full effective coverage and average pick counts of 10 to 20 per inch impart dimensional stability and high peel strength in carpets incorporating the backings and facilitate robust drying rates in manufacture of carpets.