An example method for forming a pile fabric includes: providing a primary backing material (configured as a sheet), a layer of thermoplastic material (disposed at the back side of the primary backing material), and a plurality of pile tufts extending through the primary backing material and at least partially into the layer of thermoplastic material with back stitch portions of the pile tufts being disposed at the back side of the primary backing material; and heating only the back of the pile fabric to melt the back stitch portions of the pile tufts and the layer of thermoplastic material to form a melt bond disposed at the back side of the primary backing material to secure the pile tufts to the primary backing material.

The present disclosure relates to a nonwoven fabric for primary carpet backing and a method for manufacturing same, the non-woven fabric having different colors on the two sides thereof and improved mechanical property. More specifically, the present disclosure relates to a non-woven fabric for primary carpet backing and a method for manufacturing same, wherein any one surface of the two surfaces of appears in a range of white to grey and the opposite surface thereof appears in a range of dark grey to black, so that the separate manufacture of non-woven fabrics having various colors according to carpet colors is not required, which facilitates the inventory management of the non-woven fabric, achieves color matching between a carpet pile yarn and a nonwoven fabric for primary carpet backing, and improve the efficiency of the carpet manufacturing process.

The present invention relates to a face spinneret and/or nylon face fiber having a certain shape and dimension which impart improved characteristics to the fiber, such a softer feel and a reduced sheen. In another embodiment, the invention is directed to a thatch spinneret and/or nylon thatch fiber having a certain shape and dimension which impart improved characteristics to the fiber, such a softer feel and a reduced sheen.

A method of manufacturing artificial turf includes the steps of: creating a polymer mixture including at least one polymer and a nucleating agent for crystallizing the at least one polymer, extruding the polymer mixture into a monofilament; quenching the monofilament; reheating the monofilament; stretching the reheated monofilament to form the monofilament into an artificial turf fiber, wherein during the stretching the nucleating agent boosts the creation of crystalline portions of the polymer within the monofilament; incorporating the artificial turf fiber into an artificial turf backing, thereby mechanically fixing the monofilaments of the arranged artificial turf fibers in the artificial turf backing.

This invention relates to a washable floor mat comprising a reinforcement layer. The floor mat includes a textile component and a base component. The textile component contains a reinforcement layer which dramatically reduces and/or eliminates edge deformation that often occurs as a result of the washing process. The textile component and the base component may be joined together to form a single piece floor mat. Alternatively, the textile component and the base component may be releasably attachable to one another by at least one surface attraction means to form a multi-component floor mat. The floor mat is designed to be soiled, washed, and re-used, thereby providing ideal end-use applications in areas such as building entryways.

A tufted carpet constructed by embedding pile yarns on a primary base fabric, where a ratio at which a surface of the primary base fabric is visible accounts for 5% to 85% as viewed from above the tufted carpet. The primary base fabric is formed by entangling a color fiber, a characteristic fiber, and a low melt fiber on a spunbonded base fabric or a woven base fabric. The color fiber imparts an appearance design to the surface of the primary base fabric; the characteristic fiber has at least one function selected from the group consisting of deodorization, antibacterial, anti-allergen, and anti-mite; and the low melt fiber melts at a lower temperature than melting points of the other color fiber and characteristic fiber, and fixes these fibers on the surface of the primary base fabric by thermocompression-bonding. The resulting carpet exhibits excellent shape stability, economical efficiency, and lightness.

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.

Resin dissolved or suspended in liquid is applied to a greige fabric formed with finer denier yarns forming surface loops before the fabric is bulked and after the liquid has been removed by low-temperature drying. The dried fabric is then bulked at a higher temperature setting the resin, resulting in superior loop tip resilience, and superior surface durability. Bulking and simultaneous resin setting optionally includes shrinking in area by 10-20%. Print appearance retention is also superior when printing follows bulking and setting of the resin.

Method for manufacturing a carpet or a rug, comprising the following steps: the step (S1-S2) of providing a primary backing (1), being a woven or non-woven layer comprising filaments (2) of polyethyleneterephthalate and copolymer of polyethyleneterephthalate, the coPET having a lower melting temperature than the PET and wherein said PET is available in said primary backing (1) in a higher amount than said coPET; the step of providing a glue layer (11) consisting for 50% or more out of coPET; the step of tufting yarn at least into said primary backing (1); the step of activating said glue layer (11) at least for partially fixing said yarn (12) on said primary backing (1). The invention also concerns carpets (16) and rugs that are obtained or obtainable by means of such method.

Recyclable tufted carpet products and methods of preparing the same are provided. In particular, the recyclable tufted carpet product includes a primary backing having an air permeability greater than 100 l/m.sup.2/sec at 200 Pa/20 cm.sup.2, the primary backing comprising a polyester nonwoven; a plurality of yarns tufted through the primary backing such that a pile is provided at a first surface of the primary backing and a plurality of yarn loops are provided at a second surface of the primary backing; and an adhesive that anchors the plurality of yarn loops to the second surface of the primary backing.