The carpet tile system uses preferably Aluminum Hydroxide (Al(OH).sub.3) as a flame retardant in the secondary backing of the carpet tile or in the pre-coat adhesive on the primary backing, or alternatively uses Magnesium Hydroxide (Mg(OH).sub.2). The flame retardant has been optimized to interact with the other components of the system to produce a carpet tile that achieves flammability ratings that are comparable or superior to carpet tiles with more expensive pile fibers.

The present invention relates polyester tufted carpet where the tufts are engaged with a primary polyester backing and where a polyester extrusion coating is applied to the backside of the primary backing to lock the tufts which therefore avoids the use of a latex adhesive

Disclosed is composite comprising four layers, two of the layers is a polymer film and two of the layers are non-woven materials, that is suitable for use as a primary backing material and/or a secondary backing material in the manufacture of textile carpet compositions. Also disclosed is a method for making the disclosed composite.

A carpet and a method of making a carpet are described. The carpet and the method of making the carpet does not involve the use of a latex precoat. This is useful for recycling purposes.

A tufted carpet including a tufted primary carpet backing, pile yarns tufted into the primary carpet backing, a secondary carpet backing adjoining to the primary carpet backing on the side of the primary carpet backing which exhibits backstitches and optionally a precoat and/or a polymer coat, wherein the secondary carpet backing including at least a reinforcement layer of fibers and the secondary carpet backing has an air permeability of at least 1000 l/m.sup.2.Math.s, measured according to ISO 9237:1995.

A primary carpet backing including a structure of at least three layers, wherein a first layer and a third layer including a nonwoven layer of fibers, and wherein a second layer which includes a reinforcement layer of fibers and is located between the first and the third layer, wherein the nonwoven layer of fibers of the first layer has an air permeability of at most 8000 L/m.sup.2.Math.s and the nonwoven layer of fibers of the third layer has an air permeability of at least 1000 L/m.sup.2.Math.s measured according to ISO 9237:1995, wherein the nonwoven layer of fibers of the first layer has a lower air permeability as the nonwoven layer of fibers of the third layer.

The invention comprises a method of making synthetic turf. The method comprises applying an ethylene-vinyl acetate copolymer adhesive to a first primary surface of a tufted primary backing to form a coating thereon and wherein the primary backing is tufted with a plurality of synthetic filaments to form a face pile extending outwardly from a second primary surface of the synthetic turf opposite the first primary surface and heating the ethylene-vinyl acetate copolymer adhesive to a temperature above its melting point so that the ethylene-vinyl acetate copolymer adhesive melts and at least partially flows into the primary backing. The method also comprises heating a linear low-density polyethylene film to a temperature below the softening point of the film and pressing the heated linear low-density polyethylene film into contact with the polymer coated first primary surface of the tufted primary backing. The method further comprises allowing the ethylene-vinyl acetate copolymer adhesive and the linear low-density polyethylene film to cool, whereby the linear low-density polyethylene film is adhered to the tufted primary backing.

A needle punched carpet for use in a car is disclosed. The needle punched carpet comprises at least a needle punched facing layer defining a top layer and made of staple fibers. The staple fibers comprise hollow fibers having a hollow fiber content that is at least more than 45 weight % of the total staple fibers.

This invention relates to tufted floorcovering articles, including carpet tiles and broadloom carpet. In particular, this invention relates to tufted floorcovering articles made from the family of polymers known as polyester. Specifically, this invention relates to tufted carpet tile products made from polyester. The polyester carpet tiles meet commercial performance specifications and are fully end-of-life recyclable.

A deconstructed tufted carpet having an at least partially visible primary backing. In aspects, deconstructed carpet can utilize the primary backing layer as a design element of the overall pattern and styling in order to reduce material use, waste and the ounce weight of the finished carpet and to improve the method of carpet construction. In order to expose the primary backing, at least some yarn can be pulled very low in the pattern areas to expose the primary backing layer. It is contemplated that the primary backing layer can have a color that comprises part of the overall pattern and styling of the carpet.