This invention relates to composite backing materials (e.g., polymer impregnated nonwoven fabrics) and coated abrasive articles that include such composite backing materials. This invention also relates to methods of making and using said composite backing materials and coated abrasive articles. The claimed processes and systems related to the use and manufacturing of coated abrasive articles are improved and cost effective.

Provided is an automobile interior material capable of adequately maintaining a molded shape even when remolded (demolded) at a high temperature in thermoforming, and therefore capable of significantly shortening a molding time due to the capability of high temperature demolding. An automobile interior material 1 is provided with a fiber layer 2, and a resin layer 3 laminated on one surface of the fiber layer 2. The resin layer 3 is configured to contain a thermoplastic resin having a solidifying point of 82 C. to 190 C. measured by differential scanning calorimetry.

A dimensionally stable universal floor covering includes a tufted textile substrate and a reinforcement layer to provide dimensional stability for the entire floor covering. Vacuum, mixing, and injection of compressed air assists in preparing an adhesive and fiber composition to be in the preferred condition and position before the application of pressure to form the reinforcement layer. The universal floor covering is selectively cut and transported in a roll for installation, and it can be conveniently recycled if necessary.

A carpet tile and process for making the same, wherein the carpet tile comprises a facecloth having a plurality of face yarns tufted through a primary backing, an extruded polymer secondary backing layer, and a cushion, comprising a reinforcing scrim layer within a polymer layer. The top surface and bottom surface of the carpet tile are defined by the facecloth and the cushion, respectively. A polymer-based resin is extruded onto the facecloth to form an at least substantially uniform secondary backing layer, and the cushion is laid onto the extruded polymer secondary backing layer while the extruded polymer secondary backing layer remains above a softening temperature for the resin. The entire multi-layer web is then passed through a nip to embed the reinforcing scrim layer into the extruded polymer secondary layer, and the entire web is chilled.

A method for making an artificial turf, the method comprising: providing a carrier (308) and an artificial turf fiber (501) incorporated into the carrier such that a first portion of the artificial turf fiber (506) protrudes to a back side of the carrier, a second portion of the artificial turf fiber (302) protrudes to a front side of the carrier, and a third portion of the artificial turf fiber (504) is inside the carrier; preparing a polyurethane (PU) foam reaction mixture (210) containing a reactive foam stabilizer (RFS), applying the PU foam reaction mixture on the back side of the carrier (308) to cover the artificial turf fiber (506) protruding to the back side of the carrier (308) and hardening the PU foam reaction mixture to form a flexible PU backing securing the turf fiber in place.

A dimensionally stable floor covering comprises a tufted textile substrate and a reinforcement layer attached to the textile substrate. The reinforcement layer includes an adhesive backing compound and reinforcement fibers surrounded by the adhesive backing. The fibers may form a continuous layer on the back side of the floor covering or may be dispersed within the adhesive backing compound. The adhesive backing compound may be hot water-soluble to facilitate recycling of the floor covering. The floor covering may optionally include additional backing layers (including cushions) and may be used as a broadloom carpet, a carpet tile, or other modular floor covering products. Methods of manufacturing, installing, and recycling the present floor coverings are also provided.

A carpet tile, includes a pile fabric layer, a primary backing coupled with the pile fabric layer, a secondary backing coupled with the primary backing, and a dual-layer wet-laid nonwoven mat. The dual-layer wet-laid nonwoven mat includes a first layer comprising a plurality of glass fibers and a first binder and a second layer comprising a plurality of synthetic fibers and a second binder.

A carpet tile, includes a pile fabric layer, a primary backing coupled with the pile fabric layer, a secondary backing coupled with the primary backing, and a dual-layer wet-laid nonwoven mat. The dual-layer wet-laid nonwoven mat includes a first layer comprising a plurality of glass fibers and a first binder and a second layer comprising a plurality of synthetic fibers and a second binder.

The invention relates to method for producing an artificial turf, comprising the following steps: providing a carrier material having a top and a bottom, providing a plurality of fibres, wherein each fibre comprises two ends extending from the top of the carrier material and comprising a connected region arranged in a loop-like manner at the bottom of the carrier material; feeding the carrier material with the fibres to a heated rotating calender roller; guiding the carrier material with the fibres over at least one sub-region of the surface of the heated rotating calender roller, wherein the connected regions of the fibres and the bottom of the carrier material face the calender roller; during the guiding of the carrier material with the fibres over the at least one sub-region of the surface of the heated rotating calender roller: transferring heat from the heated rotating calender roller to the carrier material with the fibres, and fusing the connected regions of the fibres with the bottom of the carrier material to the artificial turf, and removing and cooling the artificial turf. The invention further relates to an artificial turf comprising: a carrier material having a top and a bottom; a plurality of fibres, wherein each fibre comprises two ends extending from the top of the carrier material and comprising a connected region arranged in a loop-like manner at the bottom of the carrier material, wherein the carrier material is fused at the bottom to the connected regions of the fibres.