Abstract: Processes for tufting substrate or primary carpet backing using conventional double needle bars but in which the needles may be shifted less than a full gauge. Processes of the present invention may employ a conventional double needle bar tufting machine to which is added means for shifting or indexing the hook bar laterally to the machine direction of the substrate being tufted. Timing of shifting of the hook bar may be coordinated with timing of shifting of the needle bar and advance of the substrate through the machine to allow piles to be tufted into the substrate at any desired lateral position with respect to previously tufted piles. The invention creates additional pile color pattern alternatives and eliminates repetitive patterns otherwise necessitated by full gauge shifting. Elimination of repeat color sequences reduces matching color sequences on adjoining edges of adjacent carpet tiles made from such substrate which otherwise accentuate or highlight the seams between carpet tiles.

Abstract: Tile segments in desired shapes are out with great precision utilizing a computer-controlled laser and assembled on a previously prepared secondary backing with a sheet of hot melt adhesive material interposed between the assembly of segments and the secondary backing. The hot melt adhesive is then heated to fuse the assembly together while its components are securely held in their desired positions.

Abstract: A pattern-tufted, fusion-bonded carpet, particularly a backed carpet tile, having a polymeric latex primary adhesive layer and a plurality of fibrous yarns bonded to and extending from the layer to form a face surface, the fusion-bonded carpet having a woven polyester sheet material and glass fiber tissue sheet material both secured to the primary adhesive base layer, and the fusion-bonded carpet overtufted by an overtufted pattern on the face wear surface. A method of preparing a pattern-tufted, fusion-bonded carpet which comprises overtufting a fusion-bonded carpet with the fusion-bonded carpet having a primary adhesive base layer composed of a polymeric latex material and containing a woven fiberglass and a glass fiber tissue sheet material and optionally to prepare carpet tile applying a solid, thermoplastic backing to the pattern-tufted, fusion-bonded carpet material.