Abstract: A synthetic turf having a substrate and a plurality of synthetic polymer turf filaments anchored in the backing and extending therefrom, each said filament having a substantially diamond-shaped cross section.

Abstract: The disclosure relates to a floor mat and method for producing the same. The floor mat includes a plurality of tufts extending from a carrier fabric which is joined by a layer of adhesive to a backing having at least one layer of vulcanized thermoplastic elastomer. The process for production of the floor mat includes applying an olefin based adhesive to the back of a primary tufted fabric which has been preheated. The process for production includes the further separate step of applying a sheet of vulcanized thermoplastic elastomer of between about 20 and 40 mils thickness with or without a layer of reinforcing material to the preheated adhesive backed primary tufted fabric. A second layer of vulcanized thermoplastic elastomer may thereafter be applied following another heating step.

Abstract: Dual fiber carpet and matting fabrics are made of tufted ends of yarn with one end being made from standard carpet denier yarns ranging from about 10 to 30 denier per filament and total denier ranging from about 600 to 5000 denier and the second end being made from heavy monofilament fibers with a denier per filament ranging from about 100 to 500 denier and a total denier ranging from about 300 to 5000 denier per yarn bundle. Both fibers can be made from a variety of synthetic and/or natural materials. Also, a combination of at least three floor or ground covering articles, A, B, and C, for placement in and around the entryway of a building is disclosed which provides more effective cleaning ability for pedestrians' footwear, thus better ensuring the inside of the building itself remains clean.

Abstract: A method for manufacturing a vinyl-backed carpet is described wherein the carpet is assembled in a single continuous finishing line. The method includes the application of a vinyl plastisol reinforcing layer directly to the back of unfinished woven or tufted carpet material. The method allows the use of a thinner vinyl layer that results in savings in material, processing steps, and energy required for curing.

Abstract: A process for manufacturing substantially 100% nylon 6 carpet provides a nylon 6 face yarn to a nylon 6 support means so that the yarn and the support means form a carpet having a face side which is displayed when the carpet is installed and a back that binds the face yarn to the support means wherein said binding is with molten or dissolved nylon 6.

Abstract: Fiber-reinforced recycled thermoplastic composites and methods for their manufacture are presented. In a preferred embodiment, the thermoplastic composite incorporates a matrix of recycled thermoplastic and a plurality of high modulus fibers, with the recycled thermoplastic including polyethylene, polypropylene, nylon, PET and styrene-butadiene rubber, and the high modulus fibers including glass fibers, natural fibers, carbon fibers, and aramid fibers. Preferably, each of the high modulus fibers have a minimum length of approximately ½ of an inch and a modulus of approximately one million psi.

Abstract: An improved low weight cushioned flooring, floor covering, carpet, carpet tile, and method is provided. The low weight, cushioned carpet includes a low weight primary carpet having a base and a plurality of pile-forming yarns projecting outwardly from one side. A layer of reinforcement material is bonded to the base on the side opposite the pile forming yarns. The reinforcement layer is adjacent to and may be embedded in, a cushion layer of a polymer such as a polyurethane. An apparatus and process for forming the low weight cushioned carpet or carpet tile of the present invention are also provided.

Abstract: Color, pattern, design, and/or the like is applied by means of a jet dye process, or any other secondary or post pattern application process, including but not exclusively, silk screen printing and rotary printing, etc., to a carpet substrate, where the yarn in the carpet is all white (no dye applied) or where the yarn is pre-dyed with a single or multiple colors or where the yarn is treated chemically. The carpet can, for example, be made with any conventional loom weaving process or hand weaving process, for example Wilton, Axminster, spool, spool gripper, and Chenille looms, hand gun tufted, or any other conventional method.

Abstract: Poly(trimethylene terephthalate) is formed into a bulk continuous filament yarn by a process comprising:

Abstract: The present invention provides a process for producing yarn having reduced heatset shrinkage. Preferably, the fibers used in making the yarn are bicomponent fibers. The present invention also provides a process for producing yarn having reduced heatset shrinkage at reduced heat temperatures.

Abstract: Polymeric carpet and a method of making and recycling such carpet, the carpet having fibers, backing and extruded adhesive all of completely recyclable materials, the recycling being accomplished in one melting step, without a separation step.

Abstract: A carpet having nylon fibers containing a copper-based stabilizer has a polyolefin backing that partially envelops the nylon fibers. In the presence of the polyolefin backing, the copper induces degradation of the fibers and the backing. To prevent this degradation, a polyolefin backing of an ethylene/vinyl acetate copolymer which includes a stabilizing amount of a metal deactivator additive is employed. The metal deactivator is preferably 1,2-bis(3,5-di-tert-butyl-4-hydroxylhydrocinnamoyl) hydrazine. Such carpets are particularly suited for use in the manufacture of automotive carpets.

Abstract: Tufted carpeting can be manufactured employing polyurethane adhesives and cured face up without dripping, when one or more drip-reducing process steps of adding a non-Newtonian thickener to the adhesive or forming a viscosified or cured film on the outer surface of the adhesive are practiced prior to entry of the greige good into the curing oven.

Abstract: Compounding and extruding a composition, comprising 60-95 weight-% polypropylene, 0.1-10 weight-% maleated polypropylene, and 5-40 weight-% nylon or polyester, through a spinneret at a temperature in the range of 235-285° C., and drawing the resulting filament. Drawing is carried out at a draw ratio substantially lower than the draw ratio that would be necessary to obtain the same elongation with 100% polypropylene. Color pigments may be included in the composition which is compounded and extruded. In accordance with this invention, high proportions of polypropylene may be blended with nylon or polyester without detracting substantially from the good touch and luster attributable to the latter polymers. Also disclosed are carpeting and rugs in which the pile is made up of filaments produced by a process of this invention.

Abstract: The present invention relates to a cleaning pad mounted on a rotary pad base of a floor cleaning device when in use. The cleaning pad in accordance with the present invention comprises a base cloth and a fiber layer made by implanting threads made of 70 to 90 wt % cotton and 10 to 30 wt % nylon into the base cloth in a tufted manner.

Abstract: A poly(trimethylene terephthalate) short fiber having a cut length of 0.2-3 mm, and electrostatically flocked goods prepared by electrostatically flocking the poly(trimethylene terephthalate) fiber, are described. According to the present invention, there can be provided a fiber, for electrostatic flocking, which has excellent tread-proofness, scratch resistance and light resistance, and electrostatically flocked goods which have an excellent appearance.

Abstract: Laminated carpeting consisting of a secondary backing adhered to a greige good of yarn tufted into a primary backing are prepared from polyurethane adhesives by single puddle processes which allow for lowered use of polyurethane while producing carpets exhibiting excellent delamination strength. Preferably, a reactive polyurethane system is employed as a primary adhesive, and the secondary backing is skip-coated with a minor amount of a non-advancing skip coat.

Abstract: This invention relates to a cushioned floor covering article wherein the mat includes a tufted carpet placed on the top side of a foam rubber sheet and at least one foam rubber protrusion integrated within at least a portion of the bottom side of the foam rubber sheet. Such an article provides effective removal of moisture, dirt, and debris from the footwear of pedestrians through the utilization of a carpet pile component. Furthermore, the utilization of a foam rubber backing also allows for either periodic heavy duty industrial-scale laundering in such standard washing machines or periodic washing and drying in standard in-home machines, both without appreciably damaging the inventive floor covering article, such as a floor mat. Additionally, the presence of integrated foam rubber protrusions within the mat structure provides an effective cushioning effect for pedestrian comfort as well as a means to prevent slippage of the article from its contacted surface.

Abstract: Polymeric carpet and a method of making and recycling such carpet, the carpet having fibers, backing and extruded adhesive all of completely recyclable materials, the recycling being accomplished in one melting step, without a separation step.

Abstract: A fire resistant carpet backing formulation has five components of: a) a polyurethane dispersion; b) fire retardant components having at least a) ammonium polyphosphate, b) melamine, and c) a char former; c) solvents including water; d) filler, pigment and grinding aids; and e) surfactants. Preferred char formers are pentaerythritol and polysaccharides. The polyurethane dispersion is present in about 18-30% by weight, the fire retardant components of part (b) are present in about 39-61% by weight and the solvents of part (c) are present in about 9-25% by weight in the preferred embodiments. Nylon carpets made with this backing are fire retardant and meet the airline standards for fire safety.

Abstract: Fiber-reinforced recycled thermoplastic composites and methods for their manufacture are presented. In a preferred embodiment, the thermoplastic composite incorporates a matrix of recycled thermoplastic and a plurality of high modulus fibers, with the recycled thermoplastic including polyethylene, polypropylene, nylon, PET and styrene-butadiene rubber, and the high modulus fibers including glass fibers, natural fibers, carbon fibers, and aramid fibers. Preferably, each of the high modulus fibers have a minimum length of approximately ½ of an inch and a modulus of approximately one million psi.

Abstract: Tufted carpeting can be manufactured employing polyurethane adhesives and cured face up without dripping, when one or more drip-reducing process steps of adding a non-Newtonian thickener to the adhesive or forming a viscosified or cured film on the outer surface of the adhesive are practiced prior to entry of the greige good into the curing oven.

Abstract: An ozone fade resistant dyed carpet made of dyed sheath/core face fibers has a sheath substantially or completely covering the core. The sheath is composed of a fiber-forming polymer which is inherently chemically compatible and is selected from polymers that are resistant to dye migration and yet inherently chemically compatible with the core polymer. The face fibers are dyed with at least one acid dye, basic dye or disperse dye and resist ozone fading as indicated by a CIEL*a*b* total color difference from the original unexposed sample after at least 3 cycles of ozone fading that is less than one-half of the CIEL*a*b* total color difference seen for a fiber composed substantially completely of said core polyamide component that is dyed with the same dyes. The fibers may be cabled and heatset in which case even more substantial improvement in the ozone fastness is observed.

Abstract: Described is a transferrable fibrous thermal interface. The interface comprises flocked thermally conductive fibers embedded in an adhesive in substantially vertical orientation with portions of the fibers extending out of the adhesive. An encapsulant fills spaces between the portions of the fibers that extend out of the adhesive and a release liner is on at least one outer surface of the interface.

Abstract: Poly(trimethylene terephthalate) is formed into a bulk continuous filament yarn by a process comprising: Poly(trimethylene terephthalate)-based carpet having the bulk and resiliency of nylon as well as the stain resistance and low static generation of polyester is disclosed.

Abstract: A terpolymer having units of Formula I wherein X is a C2-10 alkyl, C6-12 aryl, or C4-12 alkoxy radical, d is from about 3 to about 50, R is a fluoroalkyl radical Rf—(A)v—(B)w—, Rf is a fully fluorinated straight or branched aliphatic radical optionally interrupted by at least one oxygen atom, A is a divalent radical selected from —SO2N(R″)—, —CON(R″)—, —S—, or —SO2—, where R″ is H, or a C1-6 alkyl radical, B is a divalent linear hydrocarbon radical —CtH2t—, where t is 1 to 12, Y is a divalent radical —CH2—O—, u, v, and w are each independently zero or 1, R′ is hydrogen or methyl, e is from about 0.05 to about 10, M is hydrogen, alkali metal, or ammonium, and f is from about 5 to about 40, and its use to provide soil resistance and resistance to staining by acid dyes for fiber substrates is disclosed.

Abstract: An improved cushioned carpet fabric is provided. The cushioned carpet comprises a primary carpet having a primary base and a plurality of pile-forming yarns projecting outwardly from one side. A layer of reinforcement material is bonded to the primary base on the side opposite the pile forming yarns. The reinforcement layer is adjacent to and embedded in, a cushion layer of a polymer such as a polyurethane. There is preferably no additional adhesive between the cushion layer and the layer of reinforcement material since the primary carpet fabric is mated in-situ to the polyurethane-forming composition without preheating the polyurethane-forming composition. An apparatus and process for forming the cushioned carpet fabric of the present invention are also provided.

Abstract: A composite of thermally non-adherent fluoropolymeric and non-fluoropolymeric components is created through the agency of a non-woven, fibrous binder interposed between and portionally embedded into both components. The fibers of the non-woven binder have a substantial portion of their length extending into both components and cross the interface at an angle that is substantially normal to the plane of embedment. The composite possesses good peel-adhesion behavior between the otherwise thermally non-adherent components.

Abstract: Improvements in tuft bind and/or elongation of tufted carpet may be achieved by selecting, as components of a tuft bind adhesive, one or more of: i) a polyol component comprising a low or ultra-low unsaturation polyoxypropylene polyol optionally containing up to 30 weight percent oxyethylene moieties, and ii) a chain extender component comprising 2-methyl-1,3-propanediol.

Abstract: A sheet material may be prepared and stored by applying an adhesive to one side of a first sheet and applying a second sheet to the adhesive to form a trilaminate. The trilaminate is placed into a container that is substantially free of moisture and the container is sealed so that the trilaminate can be stored in an atmosphere substantially free of moisture. The adhesive is a cross-linking polymer that reacts with moisture to form cross-linked bonds.

Abstract: A rug exhibiting a wool-like appearance made by the process comprising the steps of a. extruding a dyeable polyolefin resin comprising the reaction product of a polypropylene and an ethylene alkyl acrylate copolymer to provide an extruded fiber; b. drawing the extruded fiber by conveying the fiber among a system of unheated and heated godets; c. crimping the drawn fiber by passing the fiber into a texturing jet utilizing hot air; d. twisting at least two separate drawn and crimped fibers to provide a multi-ply carpet face yarn wherein the yarn is from about 1000 to about 8000 denier and has about 2 to about 7 twists per inch; e. heat-setting the multi-ply yarn; f. dyeing the multi-ply yarn using a space-dyeing process; and g. weaving the dyed yarn into a rug; thereby providing a rug with a wool-like appearance. The invention also provides a process for making a rug with a wool-like appearance.

Abstract: A carpet in tile or roll form is produced using an open mesh reinforced foam layer with foam nodules. The carpet is produced having a primary backing through which carpet fiber bundles are tufted and a precoat layer which locks the tufts in place to prevent easy extraction of the fibers so that a tufted face and a relatively smooth back face are provided. The foam layer with foam nodules is brought into intimate contact with the relatively smooth back face, and is substantially permanently adhered to it producing a carpet tile or roll that is substantially prevented from curling or doming (or they are significantly reduced) and may be installed without adhesive if desired. Adhering may be practiced by using a non-fused adhesive formulation which is subsequently fused at a low temperature (about 310.degree. F.

Abstract: This invention relates to a floor mat primarily for use in an outdoor environment wherein the mat includes a tufted carpet solely comprised of nylon monofilament fibers. Furthermore, this mat comprises a foam rubber backing which possesses a high level of ozone resistance and simultaneously will not appreciably stain a handler's skin or a floor's surface with carbon particles. The utilization of all monofilament nylon fibers provides for the extreme effective removal of moisture, dirt, and debris from the footwear of pedestrians and also permits easy cleaning and effective drying of the overall article. The utilization of a foam rubber backing also allows for heavy duty industrial-scale laundering in such standard washing machines without appreciably damaging either the washing machines or inventive floor mats themselves.

Abstract: A low-temperature regenerative type moisture absorbing element of fast moisture absorbing and releasing speed, capable of regenerating at 110.degree. C. or less and having a sufficiently high moisture absorbing and releasing performance in spite of small size is provided. A low-temperature regenerative type moisture absorbing element is mainly composed of high moisture absorbing and releasing polymeric compound with the content of salt type carboxyl group adjusted to a specific amount, and further comprises plural gas passages, of which regeneration temperature is 110.degree. C. or less. It is hence possible to provide a moisture absorbing element of small size, high efficiency, and energy-saving type, being excellent in moisture absorbing and releasing performance, and easily capable of removing absorbed moisture at low temperature which was impossible with the conventional moisture absorbing element.

Abstract: A carpet yarn is a plurality of fibers spun from a multiconstituent polymer alloy composed of 60 wt. % or more of nylon 6; up to about 37 wt. % of a stereoregular polyolefin having a melt flow index of from about 2 to about 100; and 3-37 wt. % of a polyolefin that is at least partially modified by one or more type of polar monomer. Upon steam heatsetting at about 124.degree. C., the yarn shrinks less than about 20%.

Abstract: A functional carpet suitable for use in an automotive vehicle. The functional carpet comprises a nonwoven fabric having piles formed throughout a whole surface of the nonwoven fabric. Each pile projects from the surface of the nonwoven fabric and is formed of at least a part of fibers constituting the nonwoven fabric. Each pile has a length ranging from 1 to 10 mm. The nonwoven fabric has a density ranging from 250 to 800 g/m.sup.2. Additionally, a fluoroplastics is adhered to a surface portion of the nonwoven fabric and extends substantially uniformly throughout the surface of the nonwoven fabric. The fluoroplastics includes linear tetrafluoroethylene telomer as a main body. The tetrafluoroethylene telomer has a number of carbon atoms ranging from 6 to 14. The amount of the fluoroplastics adhered to the surface portion of the nonwoven fabric ranges from 1.5 to 60 g/m.sup.2 in solid state.

Abstract: A storage/dispensing assembly, e.g., a roll or stack, of non-woven pressure sensitive adhesive tape comprising one or more multilayer sheets of pressure sensitive adhesive tape arranged such that the adhesive layer in the assembly of an overlying non-woven pressure sensitive adhesive tape is in direct contact with the underlying nonwoven backing layer of non-woven pressure sensitive adhesive tape. The non-woven backing layer is formed at least in part of fibers having a denier of greater than 15 so as to decrease the level of fibers disengagement when an overlying nonwoven pressure sensitive adhesive tape is removed from the assembly.

Abstract: A product and method of manufacture for an adhesive-based system to removably stick relatively flat articles on surfaces. A cured pressure-sensitive adhesive is coated on both sides of a central flat, flexible support scrim in a zoned thickness pattern which includes sufficient, continuous thickness such that the system is well suited to the removable installation of many types of articles having rough surface textures including, but not limited to, floor coverings such as woven and double-backed carpets having backs of a relatively rough texture and unitary backed carpet having a rough latex or polymeric coating and no applied secondary scrim.

Abstract: A composition for producing acid dye stain-resistant fibers includes a fiber-forming polymide, a polymer and a masterbatch concentrate which itself includes a reagent and a carrier. The reagent can be an alkal metal, alkaline earth metal or transition metal salt of 5-sulfoisophthalic acid. The carrier can be (A) a terpolymer of an alpha-monoolefin, ethylene-.alpha.,.beta. unsaturated carboxylic acid ester and an internal anhydride of an ethlenically unsaturated carboxylic acid. It can alternatively be (B) a semi-crystalline thermoplastic polyester, (C) a semi-crystalline thermoplastic polyamide, or mixtures of (B) and (C). The polymer in the composition can be (A) and mixtures of (A) and (B) and/or (C).

Abstract: The present invention is a polyurethane carpet backing prepared from a polyurethane-forming composition wherein fly ash is included as a filler material. High loadings of fly ash can be obtained without detriment to the process for preparing a polyurethane carpet backing, or adverse effect to the physical properties of the carpet backing.

Abstract: A mat, in which a pile yarn is tufted onto a base cloth and the entire or a part of pile shape is a cut pile. A part of or the entire pile yarn on a mat surface comprises a twist yarn formed by twisting two or more temporary twist yarns together. Each temporary twist yarn is formed by twisting a paralleled yarn comprising a great number of single yarns of one-kind fiber selected voluntarily from BCF nylon, vinylon, rayon, acryl, polyester and cotton; and one or more nylon monofilament single yarns. A number of kind of paralleled yarn fiber is one or two or larger in the entire temporary twist yarn of the twist yarn. In this mat, merits of both: conventional outdoor and indoor mats, can be provided and demerits of them can be compensated.

Abstract: A carpet product comprises a backing material and a face yarn, wherein the face yarn comprises synthetic carpet fibers and synthetic fibers having high moisture transport properties. Preferred face yarns are composed of a combination yarn comprising the synthetic carpet fibers commingled with the synthetic fibers having moisture transport properties. The carpet products have a texture and feel approximating that of conventional synthetic fiber facings, yet effectively transport moisture so that the carpets feel drier upon exposure to moisture.

Abstract: A method for continuous tone imaging on a mat product having a web material with a three dimensional open structure provides a mat product with a sufficiently clear image. Moreover, it is a specific aspect of the present method to provide a clear image on such a three dimensional structure without negatively affecting the characteristics of the web material having the three dimensional structure. More specifically, the present invention is directed to a method for imaging a flexible high loft matting material which can be used in providing a floor covering mat product. The present invention is also directed to the imaged mat product produced in accordance with this method.

Abstract: Stain-resistant nylon carpet is prepared by dyeing and printing cationic-dyeable nylon fibers with acid or premetallized dye. Lightfastness and depth of shade of an apparent value equal to acid dyeable nylons is obtained with superior stain resistance equal to commercially available solution dyed nylon carpeting.

Abstract: The present invention provides a splittable composite fiber having improved processability on carding and superior splitting property by a splittable composite fiber comprising at least two thermoplastic resin components, and having a structure wherein a part of at least one of the components projects from the surface of the fiber.

Abstract: A carpet having a pile layer, a support layer and a rear coating. The carpet has an intermediate layer formed from a mat comprising fibrous parts made predominantly of plastic which are in part thermoplastic and of low-melting point fibers and in part higher-melting point fibers, and melted regions providing coherence of both of the fibers, the melted regions being formed of partly melted regions of the low-melt-ing point thermoplastic fibers.

Abstract: The present invention relates to a three-dimensionally reinforced ablative/insulative composite that includes a high density fabric-based ablative layer and a low density resin-based insulative layer that is chemically bound to the ablative layer. This composite further includes stitches of a temperature-resistant thread which extend through the ablative layer and form reinforcing loops within the insulative layer. These loops are preferably chemically and mechanically bound to the insulative layer.

Abstract: A filter composite comprising a first layer of glass fibers having random orientation, the layer being porous to gas flow therethrough; a porous mat of sufficient stiffness as to support the glass fiber layer during use as a filter, the mat consisting of compacted glass fibers; and an additional porous layer carried by the mat to block escape of glass fibers or particles from the filter composite during gas flow therethrough, the composite formed to have pleated or undulating configuration.

Abstract: A transfer printed, flocked fabric includes a textile substrate, raised nylon fibers on the substrate, a black-pigmented adhesive adhering the nylon fibers to the substrate and disperse dye distributed in a pattern in upper portions of the nylon fibers and the upper portions of the nylon fibers being colored only by disperse dye, thereby forming a deep, dark, crock-fast, colored print.

Abstract: The disclosure relates to a floor mat and method for producing the same. The floor mat includes a plurality of tufts extending from a carrier fabric which is joined by a layer of adhesive to a backing having at least one layer of vulcanized thermoplastic elastomer. The process for production of the floor mat includes applying an olefin based adhesive to the back of a primary tufted fabric which has been preheated. The process for production includes the further separate step of applying a sheet of vulcanized thermoplastic elastomer of between about 20 and 40 mils thickness with or without a layer of reinforcing material to the preheated adhesive backed primary tufted fabric. A second layer of vulcanized thermoplastic elastomer may thereafter be applied following another heating step.