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: 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 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: 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: Tuftable fabrics comprise a plurality of warp and weft tapes in a balanced construction of tapes with balanced dimensions of tapes in the warp and the weft and stabilization of the fabric to impart dimensional stability. The fabrics are useful as backings for tufted carpets and especially patterned carpets and carpet tile owing to a surprising combination of tuftability, resistance to edge curl and stability during tufting.