Abstract: A primary carpet backing that is tuftable with carpet face yarn has a self-bonded or spunbonded or needlepunched nonwoven adhesive fabric needled or thermally bonded to a supporting fabric. The supporting fabric is a tuftable woven primary backing fabric comprising thermoplastic warp and weft yarns having substantially rectangular cross-sections. The nonwoven adhesive fabric comprises fibers or filaments of a thermoplastic resin having flow properties corresponding to a MI of above 30 g/10 min. as measured in accordance with ASTM D 1238 at 190° C. The nonwoven adhesive fabric also has a melting point at least about 20° C. less than a melting point of the thermoplastic of the yarns of the supporting fabric so that the nonwoven-adhesive fabric is capable of melting fully in a final product. The melted fabric can help secure pile to the backing in carpet applications.

Abstract: An improved secondary carpet backing fabric imparts increased resistance to buckling in carpets compared to conventional widely used secondary backings while providing the performance of conventional secondary carpet backings (e.g., similar peel strength, tuft bind, ease of handling). The improved backing is produced by a one-step weaving process and can be converted easily into carpet using current carpet making techniques. The inventive secondary carpet backing contains core-spun filling yarn with specific properties and is preferably woven in a leno or plain weave. Compared to carpets with conventional secondary backings, carpets with the inventive secondary backings display reduced growth in cyclic tensile testing.

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.

Abstract: Tufted carpets bonded with thermoplastic binders and having improved resistance to fuzz formation due to removal of pile yarn filaments from tuft bundles comprise one or more backings, face yarn that forms a pile on one side and stitches on an opposite side, a thermoplastic binder that binds stitches and the backing or backings, and an organic polymer that bonds filaments of the stitches. Processes for making carpets comprise applying to a stitched side of a tufted backing a liquid stitch bind composition comprising an organic polymer component, removing a liquid component of the composition to bond filaments of the stitches and bonding stitches and one or more backings with a thermoplastic binder that is melted or applied as a melt in contact with the stitched side and the backing or backings and solidified.

Abstract: A two-layer secondary carpet backing including a woven scrim layer and a fibrous layer is described. The woven scrim layer is characterized as having a low open area and a flat weave. The two-layer secondary backing is capable of having a non-abrasive, textile back surface. The secondary carpet backing is also capable of having a construction that permits high carpet manufacturing speeds due to high air permeability and is capable of providing high dimensional stability, seam strength, and delamination strength to tufted carpets made therefrom.

Abstract: Tufted carpet having good tuft bind and fuzz resistance comprising pile face yams, a backing fabric and an adhesive binder free of inorganic and latex materials. The adhesive binder comprises a thermoplastic fabric, which melts to secure the pile to the backing.

Abstract: An improved stabilizing tool includes a body with a pocket, and a roller rotatably disposed in the pocket. The body includes a fluid passageway formed axially therethrough. The passageway has a first zone wherein the pressure of the fluid is relatively high and a second zone wherein the pressure is relatively low. A first conduit provides fluid communication between the first zone and an interior of the roller for the ingress of fluid to the interior, and a second conduit provides fluid communication between the interior of the roller and the second zone for the egress of the fluid back to the fluid passageway.