Abstract: A method for preparing carpet by using polyurethane to anneal secondary backing to a greige, comprising fibers attached to a primary backing. The polyurethane monomers are mixed just prior to application to the greige primary backing allowing the relatively low viscosity polyurethane to penetrate the fibers of the primary backing to aid in fiber lock. The polyurethane is puddle between two rollers that coat a layer of polyurethane onto the greige. The polyurethane coated greige is then contacted with the secondary backing before complete polymerization to insure sufficient tack to hold the backings together resulting in a durable carpet requiring a relatively low weight of polyurethane monomers.

Abstract: A textile sheet element having selectively applied arrays of surface projection elements defining raised zones across an active surface for cleaning and/or personal care, The textile sheet element is adapted for use by itself and/or for attachment to a user manipulated support with or without a handle such as a mop head or the like.

Abstract: A process for making a noise absorber carpet including a fabric layer portion and a resinous backing layer portion including the substantially concurrent steps of continuously feeding a softened resinous backing material from a backing resin feeder onto a backing roll to form a continuous resinous backing sheet thereon, and continuously feeding a heated continuous fabric sheet via a fabric roll onto the backing sheet continuously formed on the backing roll, wherein the backing roll includes spike depressions and perforation pins on its surface, and wherein the fabric roll is located close to the backing roll to press the fabric sheet against the backing sheet as the sheets proceed between the rolls and mold spikes and perforations on the backing sheet, the backing roll being cooled to a temperature range between 10 degrees Celsius and 50 degrees Celsius with a cooling medium to harden said spikes and perforations and provide bonding between the fabric sheet and the backing sheet.

Abstract: A carpeted surface is protected with a temporary carpet protection sheet that includes a lightweight non-woven or knit fibrous material laminated with a resin backing into which at least portions of fibers of the fibrous material are embedded, or to which resin of the fibers is directly and chemically fused. Male touch fastener elements extend along the backing and are arranged in spaced apart fastening regions adjacent the longitudinal edges of the fibrous material. The male touch fastener elements are configured to be both releasably engageable with the hook-engageable fibers of the fibrous material, when the protection sheet is arranged in overlapping fashion, and releasably engageable with looped carpet tufts. A protection system features multiple lengths of such protection sheet joined by hook seaming tape.

Abstract: Disclosed is a composite carbon having a novel structure. This composite carbon has fibrous carbon which extends in the direction of the long axis, and multiple carbon nanotubes which are formed on the surface of the fibrous carbon and have a smaller diameter than the diameter of the fibrous carbon. The carbon nanotubes are formed as a group of multiple carbon nanotubes, with the lengthwise directions of each of the carbon nanotubes aligned in the same direction.

Abstract: An air-permeable cushioning floor mat includes a top surface layer, a middle air permeation layer, and a bottom anti-skid layer. The surface layer can be of various variations, including being made of carpet like materials, fabric like materials, or plastic materials. For fabric like materials, knit fabrics and brushed knit fabric can be used. For plastic materials, thermoplastic elastomer, thermoplastic rubber, or polyvinyl chloride can be used. The surface layer is bonded to the air permeation layer. The air permeation layer includes upper and lower netting portions between which multiple tiny and stiff synthetic fiber yarns are interposed. The anti-skid layer is bonded to the underside of the air permeation layer and the anti-skid layer includes a loop-and-hook type anti-skidding material. As such, the mat offers the advantages of comfortableness, resilient cushioning, and tiredness removal and shows excellent effects of air permeation and skidding resistance.

Abstract: A method of fabricating optical energy collection and conversion devices using carbon nanotubes (CNTs), and a method of anchoring CNT's into thin polymeric layers is disclosed. The basic method comprises an initial act of surrounding a plurality of substantially aligned nanostructures within at least one fluid layer of substantially uniform thickness such that a first end of the plurality of nanostructures protrudes from the fluid layer. Next, the fluid layer is altered to form an anchoring layer, thereby fastening the nanostructures within the primary anchoring layer with the first ends of the nanostructures protruding from a first surface of the primary anchoring layer. Finally, a portion of the anchoring layer is selectively removed such that a second end of the nanostructures is exposed and protrudes from the anchoring layer. The resulting product is an optically absorbent composite material having aligned nanostructures protruding from both sides of an anchoring layer.

Abstract: Substantially flame retardant-free carpets comprising poly(trimethylene terephthalate) yarn having minimal carrier and, optionally, minimal antistatic agent, are disclosed, as are methods for making such carpets.

Abstract: A multi-colored flocked article is provided having a plurality of flock and adhesive regions. Each flock region is defined by a plurality of flock fibers that are substantially the same in color and are substantially free of light dispersants, such as titanium dioxide. Further, each flock region is of a different color relative to an adjacent flock region to form a patterned, multi-colored design. Each of the plurality of adhesive regions corresponds to a flock region and includes a colored adhesive. The color of the adhesive is at least similar or substantially similar in color to the flock fibers in the corresponding flock region.

Abstract: The present invention discloses a molded laying interior material for a vehicle includes a decorative layer that faces a vehicle compartment and a buffer material layer that faces a vehicle body panel. The decorative layer has a first concavo-convex shape formed by press molding on a side of the vehicle compartment. The buffer material layer has a second concavo-convex shape formed by press molding a buffer material on a side of the vehicle body panel. The buffer material has a fiber structure in which fibers are oriented in a thickness direction in the fiber structure The decorative layer and the buffer material layer are at least laminated and integrated.

Abstract: Disclosed is a substrate for artificial turf that includes a base pad with a channel that extends across an upper surface of the pad and a tube that lies within the channel. The base pad has a generally flat lower surface and a generally flat upper surface that is spaced apart and oppositely disposed from the lower surface. The channel has a sidewall and a bottom surface, the sidewall extending from the upper surface of the base pad to the bottom surface of the channel and the bottom surface being spaced apart from the lower surface of the base pad. The tube has a sidewall defining an inner diameter surface and an outer diameter surface, with at least one aperture through the sidewall adjoining the inner diameter surface and the outer diameter surface. The channel and the tube are operable for liquid to flow through. In some instances, a radiant heating wire can extend across the upper surface of the base pad.

Abstract: There is disclosed a precoating composition for making a carpet tile comprising: at least one copolymer derived from an acrylic or methacrylic monomer and a styrenic monomer; at least one copolymer derived from an acrylic ester and a methacrylic ester; at least one thickener; and water. There is also disclosed a precoated primary backing, a floor covering and a carpet tile prepared using the composition.

Abstract: Various embodiments of the present invention provide systems and methods for etching carpets and carpet substrates. More particularly, various embodiments direct a laser beam at a carpet substrate such that energy is transferred to the carpet substrate in the form of heat. This heat alters the portion of the carpet substrate surface struck by the laser. The laser beam is guided along a pre-determined path to create a desired pattern in the carpet substrate. The desired pattern may include variations in the depth of etching of the carpet substrate.

Abstract: A cushioned, absorbent article such as a mat including a layer of absorbent, quick-drying woven textile material, a layer of viscoelastic polyurethane foam material having an open cell structure, the layer of foam material being glued and sewed to the layer of woven textile material to form a textile and foam assembly and typically a rubberized base material, glued to a foam material side of the textile and foam assembly.

Abstract: A loop material for a hook and loop type fastener is a composite nonwoven. The composite nonwoven consists of a loop layer, a backing layer, and a plurality of bond regions. The loop layer may be a carded nonwoven of thermoplastic crimped staple fiber. The staple fiber may be between 1.5 to 6.0 dTEX. The loop layer may have a basis weight of between 10 and 35 g/m2. The backing layer may be a spunbond or spunmelt nonwoven having a basis weight of 5 to 30 g/m2. The loop layer may be superimposed face-to-face with the backing layer. The plurality of bond regions joins the loop layer to the backing layer and rendering said bond regions substantially air impermeable. The bond regions comprise between 35 to 55% of a surface area of the loop material.

Abstract: Hardboards and laminates containing one or more layers of scrap carpet, with or without optional external and/or internal layers of other materials, including fibers, particles, liquids, woven and nonwoven fibrous mats, fabric and scrim, and shredded scrap carpet, and the are disclosed. The systems and methods for making the hardboard and laminates using cyclical or continuous hot consolidation are also disclosed. Various uses for the hardboard and laminates are also disclosed.

Abstract: A mat/carpet (1) comprises an upper layer (3) having a soil-removing outer surface (7) for contacting traffic passing over the mat, and a lower layer (5) located below the upper layer. The upper layer comprises textile fibers (9, 11) and is water-permeable whereby water can drain from the upper layer (3) into the lower layer (5). The lower layer (5) is arranged to collect, for subsequent removal, water that is received from the upper layer (3), and may comprise channels (50) through which water can flow in a direction generally parallel to the soil-removing outer surface (7) of the mat.

Abstract: A touch-fastening anti-skidding material includes a woven foundation layer and a plurality of synthetic yarns that is secured together by being collectively woven in the foundation layer. The foundation layer is formed by dual yarn weaving of pliable base yarns and synthetic yarns. The synthetic yarns are woven in U-shaped loops and the base yarns are woven between adjacent strands of the woven synthetic yarns to make a large area cloth. The cloth may be in a planar form without hollow opening sections or it includes open sections to facilitate air permeability. The loops of the synthetic yarns have legs extending beyond the foundation layer by a predetermined length and the synthetic yarns show rigidity strength, whereby a flexible, resilient, light-weighted, and low-cost touch-fastening anti-skidding material is formed.

Abstract: The present invention discloses a carpeted panel having a durable and flexible carpet attached thereto. The panel has a top surface, a bottom surface, and an edge between the top surface and the bottom surface A three-layer carpet is also provided, the three-layer carpet having a latex substrate layer, a fiber layer extending across and attached to one side of the substrate layer, and an adhesive layer extending across and attached to an opposite side of the substrate layer. The adhesive layer firmly attaches the three-layer carpet to the top surface, around the edge and onto the bottom surface of the panel. In addition, the fiber layer covers the latex substrate layer such that the substrate layer is not visible when viewed from the fiber layer side proximate to the edge of the panel.

Abstract: A layered, artificial surface including plural components filled with microbeads of pre-selected sizes, shapes and depths. The microbeads of the pre-selected sizes and shapes and depths provide plural different types of resistance and firmness for the artificial surface. Pre-determined chemical compounds are applied to the microbeads to change a surface charge on the microbeads, or produced with a desired surface charge to provide different interactions and thus different types of resistance and firmness for the artificial surface. The artificial surface does not require the application of a vacuum to maintain a shape or resistance.

Abstract: Matting material (1) comprises a supporting web (3) of comparatively coarse filaments (11) in which is embedded a web (5) of comparatively fine fibres (15). The upper surface of the embedded fibrous web (5) provides a shoe-wiping surface, and the coarse filaments (11) of the supporting web (3) project above the upper surface of the embedded web (5) to provide shoe-scraping elements.

Abstract: Certain embodiments utilize carpet tiles of varying sizes and/or shapes that are connected together using connectors to form a carpet tile installation. In some instances, the carpet tiles used in the carpet tile installation have different colors, patterns, shapes, and/or styles. In some embodiments, carpet tiles of a standard size and shape, such as one-half square meter carpet tiles, are partitioned into carpet tile fractions. In certain embodiments, these carpet tile fractions are used in conjunction with larger carpet tiles in a carpet tile installation. In other embodiments, these carpet tile fractions may be connected to other carpet tile fractions to form a combination carpet tile that is then used in a carpet tile installation. Among other things, the use of different sized and/or shaped carpet tiles increases the randomness or diversity and/or improves other aspects of the appearance of the floor coverings formed by the carpet tile installations.

Abstract: An artificial turf filament has a cross-section that includes a central area and two wing areas integral with said central area. Further a bundle of a plurality of artificial turf filaments is proposed, wherein the artificial turf filaments are held together by one or more wrapping filaments wrapped around said artificial turf filaments. The wrapping filaments cross each other at cross points, and are bonded, preferably releasable bonded, to one another at said cross points. Also the wrapping filaments are bonded, preferably releasable bonded, to said artificial turf filaments.

Abstract: Artificial turf stock materials useful for artificial turf stock backfixing, including: a hotmelt made of: a) from 5% to 100% by weight of at least one amorphous poly-?-olefin, b) from 0% to 100% by weight of at least one modified amorphous poly-?-olefin, c) from 0% to 40% by weight of at least one resin, d) from 5% to 15% by weight of at least one modified crystalline polypropylene, e) from 0% to 20% by weight of at least one crystalline polyolefin, f) from 0% to 80% by weight of fillers or pigments, g) from 0% to 20% by weight of at least one flame retardant, and h) from 0% to 20% by weight of at least one wax, where ribbon yarn of polyethylene, polypropene, polyester, polymide, or an interpolymer is bound together with the hotmelt in an artificial turf stock material.

Abstract: A frothable aqueous composition that includes a polymeric binder, and a froth aid that includes a polypropylene glycol, a polypropylene glycol ether, or a combination thereof, where the froth aid has a weight average molecular weight of 130 to 2000, as a carpet backing.

Abstract: Disclosed are a carpet for a vehicle and a method of manufacturing the same. A first material is scored to define a gap. A portion of the first material interior to the gap is compressed, and then folded out of the gap. A second material is adhered to the first material. The second material may be adhered to the compressed portion of the first material. The volume of the compressed portion may be decreased by about half. The first material may be a sound-absorbing material.

Abstract: The present invention pertains to carpet and methods of making carpet. In one aspect, the carpet includes (a) a primary backing which has a face and a back surface, (b) a plurality of fibers attached to the primary backing and extending from the face of the primary backing and exposed at the back surface of the primary backing, (c) an adhesive backing, (d) an optional secondary backing adjacent to the adhesive backing, and (e) at least one homogeneously branched ethylene polymer. The method includes extrusion coating at least one homogeneously branched ethylene polymer onto the back surface of a primary backing to provide an adhesive backing. The method can include additional steps or procedures, either separately or in various combinations. Additional steps and procedures include washing or scouring the primary backing and fibers prior to the extrusion step, and utilizing implosion agents. The preferred homogeneously branched ethylene polymer is a substantially linear ethylene polymer.

Abstract: A sanitary napkin comprising a topsheet having a body-facing side and comprising a plurality of discrete tufts of fibrous material. The topsheet has a lotion composition applied to at least a portion of the body-facing side thereof. An absorbent core is in fluid communication with the topsheet, the absorbent core having an average thickness of less than about 10 mm, and a free absorbent capacity of from about 4 to about 125 grams per gram.

Abstract: An acoustic composite comprises a flow resistive substrate having a solid acoustic barrier material bonded to at least a portion of a major surface of the flow resistive substrate; wherein the acoustic barrier material has a density greater than about 1 g/cm3 and the acoustic composite has a porosity between about 0.002% and about 50%.

Abstract: The object of the invention is to provide a method which is as simple and economical as possible for manufacturing a tufted product, in particular a tufted top layer of a carpet, having improved nep adhesion properties. For this purpose splittable fibers are used which split on or in the region of the puncture site during tufting.

Abstract: A carpet material with at least one of its components made easier for recycle by use of an adhesive which can be selectively altered to change the adhesion strength to allow component carpet layers to be separated.

Abstract: A floor mat and a method and apparatus for making a floor mat having desirable absorptive characteristics and constructed significantly of recycled or post industrial/consumer materials. A floor mat may be made of a base layer, a padding layer and a face layer. The base layer may comprise at least a portion of reprocessed rubber buffings formed to have an upper surface, a lower surface, and a plurality of nibs. The face layer may comprise a carper formed of at least a portion of which is post industrial and/or post consumer PET. The padding layer may be positioned between the base layer and the face layer comprising at least a portion of post industrial and/or post consumer PET.

Abstract: The present invention pertains to carpet and carpet tile. In one aspect, the carpet includes (a) a primary backing which has a face and a back surface, (b) a plurality of fibers attached to the primary backing and extending from the face of the primary backing and exposed at the back surface of the primary backing, (c) an adhesive backing, (d) an optional secondary backing adjacent to the adhesive backing, and (e) at least one non-chlorinated, non-polyvinyl butyral thermoplastic polymer or composition having a specific growth tension at 40 C and a specific residual stress at 25% strain. Additional steps and procedures include washing or scouring the primary backing and fibers prior to the extrusion step, and utilizing implosion agents. The preferred olefin block copolymer are ethylene based block interpolymers. The constructions and methods described herein are particularly suited for making tufted, broad-loom carpet having improved abrasion resistance.

Abstract: A composite made of earth based bio-fibers and polymers is described, wherein the fibers and/or particles are taken from peats or lignite and the polymers are chosen from the group of thermoplastic polymers.

Abstract: A double-face velour fabric article consists of a fabric body having a technical face formed by a filament stitch yarn and a technical back formed by a filament loop yarn. The filament stitch yarn includes a heat sensitive material, e.g. a hot melt material or a heat shrinkable material, and/or an elastomeric material, such as spandex. The fabric body has a velour surface formed at both the technical back and the technical face. Raised fibers of at least one of the technical face and the technical back may be entangled, including in and/or through interstices of the fabric body, toward the other of the technical face and the technical back, e.g., by a hydroentanglement process applied after finishing. The fabric body has permeability of about 80 ft3/ft2/min, or less, under a pressure difference of ½ inch of water across the fabric body.

Abstract: The present invention pertains to carpet and methods of making and recycling carpet. In one aspect, the carpet includes: a primary backing which has a face and a back surface; a plurality of fibers attached to the primary backing and extending from the face of the primary backing and exposed at the back surface of the primary backing; an adhesive composition backing; and an optional secondary backing adjacent to the adhesive backing. The method of making carpet includes extrusion coating the adhesive composition onto the back surface of a primary backing to form the adhesive composition backing. The method of recycling carpet can recover one or more polymeric carpet components.

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: A process is described for treating a nonwoven fabric to improve the gripping ability of the fabric during the preparation of tufted carpets. The process includes the steps of applying an elastomeric binder to the fabric, treating the fabric to provide a series of depressions or holes in a pattern consistent with the tufting needle pattern to be subsequently applied, and then curing the binder. The resultant fabric has a pattern of holes or depressions which are essentially free of binder with excess binder squeezed from the depressions forming rings around the depressions. When the tufting needle is inserted into the depression or hole, the elastomeric ring surrounding the hole expands. Upon retraction of the needle, the elastomeric ring contracts and exerts a firm grip on the tuft in the hole.

Abstract: A carpet has a layer of tufting supported on a primary backing layer. A breathable membrane is disposed along an interface between the primary backing layer and a secondary backing layer. A breathable membrane is disposed along an interface between the tufting layer and the backing layer, and adhesively secures the layer of tufting to the backing layer. The breathable membrane is permeable to water vapor but impervious to liquid water, while both the tufting layer and the backing layer are permeable to water vapor. In an alternative embodiment of the invention, a laminated barrier which includes the membrane, may be made of fibers, yarns, cross-laid scrim, or plastic netting, and the breathable membrane may be protected from abrasion with a floor by means of an apertured film laminated to the membrane.

Abstract: Polyurethane carpet backings are made using a polyurethane-forming composition that includes hydroxymethyl-containing polyester polyols. The formulation allows a significant replacement of conventional polyols with polyols derived from annually renewable resources, while maintaining important properties like edge curl, tuftbind, viscosity and good curing rates.

Abstract: A composite ply is provided by the present invention, with a substrate having a plurality of fibers extending from at least one side and a plurality of fiber fasteners each being formed by the adhering together with a bonding agent of adjacent groupings of fibers. The bonding agent increases the form-holding characteristics of the fiber fasteners, such that the fastening qualities are enhanced. Advantageously, soft fiber can be stiffened to a certain level and used as fasteners that resist crushing during engagement of the fasteners. After the fastener engagement process is done, the engaged fasteners may be crushed and further interlocked when compressed within a layup with a increased compression load.

Abstract: A loop material for a hook and loop type fastener is a composite nonwoven. The composite nonwoven consists of a loop layer, a backing layer, and a plurality of bond regions. The loop layer may be a carded nonwoven of thermoplastic crimped staple fiber. The staple fiber may be between 1.5 to 6.0 dTEX. The loop layer may have a basis weight of between 10 and 35 g/m2. The backing layer may be a spunbond or spunmelt nonwoven having a basis weight of 5 to 30 g/m2. The loop layer may be superimposed face-to-face with the backing layer. The plurality of bond regions joins the loop layer to the backing layer and rendering said bond regions substantially air impermeable. The bond regions comprise between 35 to 55% of a surface area of the loop material.

Abstract: A laminate web comprising a first and second precursor webs, at least the first precursor web being a nonwoven web, the laminate web having a first side, the first side comprising the second precursor web and at least one discrete tuft, each of the discrete tufts having a linear orientation defining a longitudinal axis and comprising a plurality of tufted fibers being integral extensions of the first precursor web and extending through the second precursor web; and a second side, the second side comprising the first precursor web.

Abstract: A durable and wear resistant synthetic sports field having at least one strip having a plurality of fibrillated polypropylene strands tufted within a multilayer backing material. The strands are tufted in a wide variety of pile heights, patterns, gauges, and stitch patterns depending upon end use. The multiplayer backing material has a top mesh polypropylene layer at least three layers of a backing material coated with a secondary coating used to contain the ends of the plurality of strands. The strips are placed onto a fine aggregate layer placed over a coarse aggregate layer and a geotextile fabric. The geotextile fabric is placed onto a compacted and leveled subgrade. A ground rubber infill, with or without sand particles and diatomaceous earth, is introduced onto the strips. In alternative arrangements, a series of perforated drains and drain tiles may be introduced to the coarse aggregate layer to promote drainage.

Abstract: The present invention relates to the use of a vulcanised thermoplastic elastomer or styrene-ethylene-butadiene-styrene polymer (SEBS) as infill material in artificial turf systems. Artificial turf has achieved growing popularity in recent years, particularly for football fields. The vulcanised thermoplastic elastomer comprises a polyolefin and a rubber wherein the rubber is dynamically vulcanised by the use of a curing agent. The polyolefin is chosen from polyethylene or polypropylene and the rubber is chosen from EPDM or EPM. The rubber is dynamically vulcanised by a curing agent chosen from sulfur, sulfurous compounds, metal oxides, maleimides, phenol resins, silanes or peroxides.

Abstract: Low weight and non-square carpet tile suitable for use in mass transit vehicles, particularly passenger aircraft. The carpet tile preferably weighs less than about 82 ounces per square yard. The carpet tile of this invention may have a carpet pile and at least one backing layer. The backing layer may use a low weight filler material. The carpet tiles satisfy transportation industry standards for flame, smoke and toxicity.

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: In one embodiment, a flocked article is provided that includes an elastomeric film and a plurality of flock fibers on a flocked surface of the film. The flock fibers are embedded in the film.

Abstract: Devices, systems and methods for fabricating improved ceramic composite turbine shrouds with abradable seals are disclosed. A high temperature seal with an abradable coating is provided. The seal comprises a three-dimensional, high-density woven composite base structure recessed below the abradable coating, with loops incorporated in and protruding from the base structure. The abradable coating is integrally attached to the base structure via the loops. Additionally, a graded density seal is provided with a three-dimensional, low-density woven composite structure. The low-density structure is abradable. A three-dimensional, high-density woven composite base structure is recessed below the low-density structure, with the low-density structure integrally attached to the base structure via weaving.

Abstract: A velour fabric article consists of a fabric body having a technical face formed by a filament stitch yarn and a technical back formed by a loop yarn. The filament stitch yarn includes a heat sensitive material, e.g. a hot melt material or a heat shrinkable material, and/or an elastomeric material, such as spandex. The loop yarn includes flame retardant material, such as M-Aramide fiber. The fabric body has a velour surface formed at one or both of the technical back and the technical face. Raised fibers of at least one of the technical face and the technical back may be entangled, including in and/or through interstices of the fabric body, toward the other of the technical face and the technical back, e.g., by a hydroentanglement process applied after finishing. The fabric body has permeability of about 90 ft3/ft2/min, or less, under a pressure difference of ½ inch of water across the fabric body.